Methods and systems for inline mixing of hydrocarbon liquids

ABSTRACT

Embodiments include systems and methods of in-line mixing of hydrocarbon liquids from a plurality of tanks into a single pipeline. According to an embodiment, a method of admixing hydrocarbon liquids from a plurality of tanks into a single pipeline to provide in-line mixing thereof includes determining a ratio of a second fluid flow to a first fluid flow based on signals received from a tank flow meter in fluid communication with the second fluid flow and a booster flow meter in fluid communication with a blended fluid flow. The blended fluid flow includes a blended flow of the first fluid flow and the second fluid flow. The method further includes comparing the determined ratio to a pre-selected set point ratio thereby to determine a modified flow of the second fluid flow to drive the ratio toward the pre-selected set point ratio. The method further includes controlling a variable speed drive connected to a pump thereby to control the second fluid flow through the pump based on the determined modified flow, the pump being in fluid communication with the second fluid flow.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. Non-Provisional applicationSer. No. 17/247,704, filed Dec. 21, 2020, titled “METHODS AND SYSTEMSFOR INLINE MIXING OF HYDROCARBON LIQUIDS,” now U.S. patent Ser. No.10,990,114, issued Apr. 27, 2021, which claims priority to, and thebenefit of U.S. Provisional Application No. 62/954,960 filed Dec. 30,2019, titled “METHOD AND APPARATUS FOR INLINE MIXING OF HEAVY CRUDE,”U.S. Provisional 62/705,538 filed Jul. 2, 2020, titled “METHODS ANDSYSTEMS FOR INLINE MIXING OF PETROLEUM LIQUIDS,” and U.S. Provisional63/198,356 filed Oct. 13, 2020, titled “METHODS AND SYSTEMS FOR INLINEMIXING OF PETROLEUM LIQUIDS,” the disclosures of which are incorporatedherein by reference in their entirety.

FIELD OF DISCLOSURE

The disclosure herein relates to systems and methods for providingin-line mixing of hydrocarbon liquids, and one or more embodiments ofsuch systems and methods may be suitable for providing multi-componentmixing of two or more hydrocarbon liquids.

BACKGROUND

Different types of hydrocarbon liquids, such as petroleum and renewableliquid products (e.g., such as crude oil), are often mixed upstream of arefinery to reduce the viscosity of heavy crude and maximize capacity,or to create a desired set of properties (TAN, sulfur, etc.). Given themultitude of crude types, the potential mixtures and component ratiosare numerous. In some situations, multiple different types ofhydrocarbon liquids, e.g., crude oil and renewable products, fromdifferent tanks may need to be mixed in a particular ratio. Further,there may also be a need to create a desired mixture on demand and shipthe mixture through a pipeline as one homogenous product. In suchexamples, the mixing of different types of hydrocarbon liquid, e.g.,crude and renewable liquid, may be performed at a pipeline originationstation. Often, the pipeline origination station may include a tank farm(e.g., having multiple tanks for storage and mixing of the crude oils)and extensive piping capable of transporting hydrocarbon liquids fromeach of the tanks to one or more mainline booster pumps, which raise thehydrocarbon liquids to high pressures for traveling on a long pipeline.

Historically, crude mixing occurred by blending the crude oils in one ormore tanks. Tank mixing is the most common form of crude mixing in theoil and gas industry. While relatively inexpensive, such methods haveseveral undesirable drawbacks. For example, the extent and/or accuracyof the mixing may be less precise (e.g., having an error rate of +/−about 10% based on a target set point). Such methods typically requirean entire tank to be dedicated to blending the crude oils along withseparate distribution piping therefrom. In addition, the mixed crudeproduct tends to stratify in the tank without the use of tank mixers,which also require additional capital investment. Further, the mixedcrude product is generally limited to a 50/50 blend ratio.

An alternative to tank mixing is parallel mixing, which uses two pumpsto pump two controlled feed streams (e.g., one pump per feed stream) ondemand from separate tanks and into the pipeline. While parallel mixingis typically more precise than tank mixing, it is also more difficult tocontrol because both streams are pumped by booster pumps into a commonstream. Typically, the two pumped streams are individually controlled byvariable speed pumps or pumps with flow control valves; therefore, thetwo sets of independent controls may interfere with each other and/ormay have difficulty reaching steady state if not programmed correctly.

Applicant has recognized, however, that in parallel mixing operations,both streams need to be boosted to about 50-200 psi of pressure in thetank farm to provide adequate suction pressure to a mainline boosterpump that is positioned downstream of the boosters. Even if one streamoperates at a fixed flow while the other varies, the need to boost thepressure of each stream to about 50-200 psi may require high horsepowerboost pumps dedicated to each line. Such dedicated pumps may be neededto supply streams at adequate pressure to the mainline pumps and mayrequire significant capital investment. From a commercial standpoint,for example, parallel mixing operations require much moreinfrastructure, representing a 180% to 200% increase in cost differencecompared to the in-line mixing systems disclosed herein. Therefore,there is a need in the industry for accurate and cost-effective blendingmethods and systems for crude and other hydrocarbon liquid products.

SUMMARY

The disclosure herein provides embodiments of systems and methods forin-line fluid mixing of hydrocarbon liquids. In particular, in one ormore embodiments the disclosure provides in-line mixing systems that maybe positioned at a tank farm, including a one or more tanks positionedto store one or more hydrocarbon liquids. Such an embodiment of anin-line mixing system is positioned to admix two or more of thosehydrocarbon liquids contained within the plurality of tanks to provide ablended mixture within a single pipeline. In some embodiments, thesystems and methods of the disclosure may provide for in-line mixing ofat least two hydrocarbon liquids, at least three hydrocarbon liquids, ormore to form a blended fluid flow in a single pipeline, e.g., which maybe referred to herein as two-component blend, three-component blends, ora blend containing more than three hydrocarbon liquids.

In one or more embodiments, an in-line fluid mixing system may bepositioned at a tank farm to admix hydrocarbon liquids from a pluralityof tanks into a single pipeline. For example, a first tank may bepositioned in a tank farm and may contain a first fluid therein. In someembodiments, the first tank may have a first output pipe connected tothe first tank proximate a bottom portion thereof. The first output pipemay be in fluid communication with the first fluid to transport a flowof the first fluid from the first tank through the first output pipe ata first pressure. The system also may include a second tank positionedin the tank farm and containing a second fluid therein. The second tankmay have a second output pipe connected to the second tank proximate abottom portion thereof. The second output pipe may be in fluidcommunication with the second fluid to transport a flow of the secondfluid from the second tank through the second output pipe at a secondpressure.

In some embodiments of the disclosure, for example, the system mayinclude a first pump having an inlet and an outlet, and the inlet of thepump may be connected to the second output pipe to increase pressure ofthe flow of the second fluid from the second pressure to a pump pressureat the outlet. Systems as disclosed herein, for example, may include amixing booster pipe connected to the outlet of the pump to transport theflow of the second fluid therethrough. A system according to one or moreembodiments of the disclosure may include a blended fluid pipe connectedto and in fluid communication with the first output pipe and the mixingbooster pipe to admix the flow of first fluid at the first pressure andthe flow of second fluid at the second pressure into a blended fluidflow.

In one or more embodiments, for example, in-line mixing systems mayinclude a tank flow meter connected to the mixing booster pipe andpositioned between the pump and the blended fluid pipe to measure flowrate of the flow of the second fluid between the pump and the blendedfluid pipe. Systems also may include a flow control valve connected tothe mixing booster pipe between the tank flow meter and the blendedfluid pipe to control the flow of the second fluid between the pump andthe blended fluid pipe. In some embodiments, in-line mixing systems ofthe disclosure also may include a second pump having an inlet in fluidcommunication with the blended fluid pipe and an outlet. The second pumpmay have a greater horsepower than the first pump. A booster flow metermay be in fluid communication with the blended fluid pipe and positionedto measure total flow rate of the blended fluid flow transported throughthe blended fluid pipe. A pipeline also may be connected to the outletof the booster pump to transport the blended fluid flow therethrough andexternal of the tank farm. The pipeline may be configured to transportthe blended fluid across long distances at high pressures, for example,to other plants and industrial facilities.

In some embodiments, the first pressure may result from force of gravityon the first fluid contained in the first tank. In-line mixing systemsmay include one or more controllers in communication with the tank flowmeter and the booster flow meter. In certain embodiments, for example,the one or more controllers may be configured to determine a ratio ofthe flow of second fluid to the flow of first fluid responsive to one ormore signals received from the tank flow meter and the booster flowmeter. Some embodiments of systems may include a variable speed driveconnected to the first pump to control pump speed to thereby adjust theflow of the second fluid through the first pump. For example,embodiments of systems of the disclosure also may include a programmablelogic controller in communication with the variable speed drive andconfigured to control the variable speed drive. The one or morecontrollers may be configured to compare the ratio to a pre-selected setpoint ratio, determine a modified flow of the second fluid to drive theratio toward the pre-selected set point ratio, and send a control signalto the one or more controllers to adjust the variable speed drive basedon the determined modified flow of the second fluid.

Other embodiments of the disclosure relate to methods of admixinghydrocarbon liquids from a plurality of tanks into a single pipeline toprovide in-line mixing thereof. Some embodiments of methods, forexample, may include determining a ratio of a second fluid flow to afirst fluid flow based on signals received from a tank flow meter influid communication with the second fluid flow and a booster flow meterin fluid communication with a blended fluid flow. The blended fluidflow, for example, may include a blended flow of the first fluid flowand the second fluid flow. In some embodiments of the disclosure, amethod also may include comparing the determined ratio to a pre-selectedset point ratio thereby to determine a modified flow of the second fluidflow to drive the ratio toward the pre-selected set point ratio. Infurther embodiments, the method may include controlling a variable speeddrive connected to a pump thereby to control the second fluid flowthrough the pump based on the determined modified flow, the pump beingin fluid communication with the second fluid flow.

In some embodiments, methods as described herein may include maintainingthe difference between the calculated ratio and the pre-selected setpoint ratio within a pre-selected error range. In some embodiments, forexample, the pre-selected error range may be in the range of about 1.0%to −1.0%. In certain other embodiments, the pre-selected error range maybe in the range of about 0.05% to about −0.05%. Methods according to thedisclosure also may include adjusting a flow control valve in fluidcommunication with the second fluid flow to thereby control the secondfluid flow based on the determined modified flow. In some embodiments,for example, methods may include adjusting a flow control valve in fluidcommunication with the second fluid flow to thereby maintain pressure atthe tank flow meter between about 15 psi and about 25 psi.

In some embodiments, methods of admixing hydrocarbon liquids from aplurality of tanks into a single pipeline to provide in-line mixingthereof are described herein. The method may include permitting a firsthydrocarbon fluid to flow from a first crude tank at a tank farm to afirst output pipe. The first hydrocarbon fluid may have a first pressurein the first output pipe. The method may include pumping a secondhydrocarbon fluid from a second crude tank at the tank farm to a secondtank mixing booster pipe. The second hydrocarbon fluid may have a secondpressure in the second tank mixing booster pipe. The method may includeadmixing the first hydrocarbon fluid from the first output pipe and thesecond hydrocarbon fluid from the second tank mixing booster pipe into ablended fluid pipe to create a blended fluid. The method may includedetermining a flow rate of the second hydrocarbon fluid in the secondtank mixing booster pipe with a tank flow meter that measures flow ratein the second tank mixing booster pipe. The method may includedetermining a flow rate of the blended fluid in the blended fluid pipewith a booster flow meter that measures flow rate in the blended fluidpipe. The method may include determining a flow rate of the firsthydrocarbon fluid in the first output pipe from the second hydrocarbonfluid flow rate and the blended fluid flow rate. The method may includecomparing a ratio of the second hydrocarbon fluid flow rate and thefirst hydrocarbon fluid flow rate to a pre-selected set point ratio. Themethod may include controlling the second pressure of the secondhydrocarbon fluid to modify the second flow rate and drive the ratiotoward the pre-selected set point ratio. The method may include pumpingthe blended fluid through a downstream pipeline.

In another embodiment, a method of admixing hydrocarbon liquids from aplurality of tanks into a single pipeline to provide in-line mixingthereof is described herein. The method may include permitting a firsthydrocarbon fluid to flow from a first crude tank at a tank farm to afirst output pipe. The first hydrocarbon fluid may have a first pressurein the first output pipe. The method may include pumping a secondhydrocarbon fluid from a second crude tank at the tank farm to a secondtank mixing booster pipe. The second hydrocarbon fluid having a secondpressure in the second tank mixing booster pipe. The method may includepumping a third hydrocarbon fluid from a third crude tank at the tankfarm to a third tank mixing booster pipe. The third hydrocarbon fluidhaving a third pressure in the third tank mixing booster pipe. Themethod may include admixing the first hydrocarbon fluid from the firstoutput pipe, the second hydrocarbon fluid from the second tank mixingbooster pipe, and the third hydrocarbon fluid from the third tank mixingbooster pipe into a blended fluid pipe to create a blended fluid. Themethod may include determining a flow rate of the second hydrocarbonfluid in the second tank mixing booster pipe with a second tank flowmeter that measures flow rate in the second tank mixing booster pipe.The method may include determining a flow rate of the third hydrocarbonfluid in the third tank mixing booster pipe with a third tank flow meterthat measures flow rate in the third tank mixing booster pipe. Themethod may include determining a flow rate of the blended fluid in theblended fluid pipe with a booster flow meter that measures flow rate inthe blended fluid pipe. The method may include determining a flow rateof the first hydrocarbon fluid in the first output pipe based on thesecond hydrocarbon fluid flow rate, the third hydrocarbon fluid flowrate and the blended fluid flow rate. The method may include comparingpercentages of the first hydrocarbon fluid flow rate, second hydrocarbonfluid flow rate, and third hydrocarbon fluid flow rate in the blendedfluid flow to pre-selected percentages. The method may includecontrolling at least one of the second pressure of the secondhydrocarbon fluid or the third pressure of the third hydrocarbon fluidto modify flowrates of the second hydrocarbon fluid and the thirdhydrocarbon fluid and drive the percentages toward the pre-selectedpercentages. The method may include pumping the blended fluid through adownstream pipeline.

Still other aspects and advantages of these embodiments and otherembodiments, are discussed in detail herein. Moreover, it is to beunderstood that both the foregoing information and the followingdetailed description provide merely illustrative examples of variousaspects and embodiments, and are intended to provide an overview orframework for understanding the nature and character of the claimedaspects and embodiments. Accordingly, these and other objects, alongwith advantages and features of the present disclosure herein disclosed,will become apparent through reference to the following description andthe accompanying drawings. Furthermore, it is to be understood that thefeatures of the various embodiments described herein are not mutuallyexclusive and may exist in various combinations and permutations.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the disclosure willbecome better understood with regard to the following descriptions,claims, and accompanying drawings. It is to be noted, however, that thedrawings illustrate only several embodiments of the disclosure and,therefore, are not to be considered limiting of the scope of thedisclosure.

FIG. 1 is a schematic diagram of a two-component in-line mixing systempositioned at a tank farm to admix two hydrocarbon liquids from separatetanks into a single pipeline according to an embodiment of thedisclosure.

FIG. 2 is a schematic diagram of a three-component in-line mixing systempositioned at a tank farm to admix three hydrocarbon liquids fromseparate tanks into a single pipeline according to an embodiment of thedisclosure.

FIG. 3 is a schematic diagram of a three-component in-line mixing systempositioned at a tank farm to admix three hydrocarbon liquids fromseparate tanks into a single pipeline according to an embodiment of thedisclosure.

FIG. 4 is a schematic diagram of a three-component in-line mixing systempositioned at a tank farm admix three hydrocarbon liquids from separatetanks into a single pipeline.

FIG. 5 is a schematic diagram of a control system on a single fluidline, the control system including tank output pipe, a pump, a mixingbooster pipe, a blended fluid pipe, a tank flow meter, a flow controlvalve, a recirculation pipe, and a one-way valve disposed in therecirculation pipe, according to an embodiment of the disclosure.

FIGS. 6A through 6B are schematic diagrams of a two-component in-linemixing system positioned at a tank farm to admix two hydrocarbon liquidsfrom separate tanks into a single pipeline according to an embodiment ofthe disclosure.

FIGS. 7A through 7B are schematic diagrams of a three-component in-linemixing system positioned at a tank farm to admix three hydrocarbonliquids from separate tanks into a single pipeline according to anembodiment of the disclosure.

FIGS. 8A through 8B are schematic diagrams of a multi-component in-linemixing system positioned at a tank farm to admix two or more hydrocarbonliquids from separate tanks into a single pipeline according to anembodiment of the disclosure.

FIG. 9 is a simplified diagram illustrating a control system formanaging a multi-component in-line mixing system according to anembodiment of the disclosure.

FIG. 10 is another simplified diagram illustrating a control system formanaging a multi-component in-line mixing system according to anembodiment of the disclosure.

FIG. 11 is another simplified diagram illustrating a control system formanaging a multi-component in-line mixing system according to anembodiment of the disclosure.

FIG. 12 is a flow diagram, implemented in a controller, for managing amulti-component in-line mixing system according to an embodiment of thedisclosure.

FIG. 13 is a flow diagram, implemented in a controller, for managing amulti-component in-line mixing system according to an embodiment of thedisclosure.

DETAILED DESCRIPTION

So that the manner in which the features and advantages of theembodiments of the systems and methods disclosed herein, as well asothers that will become apparent, may be understood in more detail, amore particular description of embodiments of systems and methodsbriefly summarized above may be had by reference to the followingdetailed description of embodiments thereof, in which one or more arefurther illustrated in the appended drawings, which form a part of thisspecification. It is to be noted, however, that the drawings illustrateonly various embodiments of the systems and methods disclosed herein andare therefore not to be considered limiting of the scope of the systemsand methods disclosed herein as it may include other effectiveembodiments as well.

The present disclosure provides embodiments of systems and methods forin-line fluid mixing of hydrocarbon liquids. “Hydrocarbon liquids” asused herein, may refer to petroleum liquids, renewable liquids, andother hydrocarbon based liquids. “Petroleum liquids” as used herein, mayrefer to liquid products containing crude oil, petroleum products,and/or distillates or refinery intermediates. For example, crude oilcontains a combination of hydrocarbons having different boiling pointsthat exists as a viscous liquid in underground geological formations andat the surface. Petroleum products, for example, may be produced byprocessing crude oil and other liquids at petroleum refineries, byextracting liquid hydrocarbons at natural gas processing plants, and byproducing finished petroleum products at industrial facilities. Refineryintermediates, for example, may refer to any refinery hydrocarbon thatis not crude oil or a finished petroleum product (e.g., such asgasoline), including all refinery output from distillation (e.g.,distillates or distillation fractions) or from other conversion units.In some non-limiting embodiments of systems and methods, petroleumliquids may include heavy blend crude oil used at a pipeline originationstation. Heavy blend crude oil is typically characterized as having anAmerican Petroleum Institute (API) gravity of about 30 degrees or below.However, in other embodiments, the petroleum liquids may include lighterblend crude oils, for example, having an API gravity of greater than 30degrees. “Renewable liquids” as used herein, may refer to liquidproducts containing plant and/or animal derived feedstock. Further, therenewable liquids may be hydrocarbon based. For example, a renewableliquid may be a pyrolysis oil, oleaginous feedstock, biomass derivedfeedstock, or other liquids, as will be understood by those skilled inthe art. The API gravity of renewable liquids may vary depending on thetype of renewable liquid.

In particular, in one or more embodiments, the disclosure provides anin-line mixing system that may be positioned at a tank farm thatincludes a plurality of tanks configured to store one or morehydrocarbon liquids. Such an in-line mixing system may provide admixingof two or more of those hydrocarbon liquids contained within theplurality of tanks to provide a blended mixture within a singlepipeline. In some embodiments, the systems and methods of the disclosuremay provide for in-line mixing of at least two hydrocarbon liquids, atleast three hydrocarbon liquids, or more than three hydrocarbon liquidsto form a blended fluid flow in a single pipeline, e.g., which may bereferred to herein as two-component blends, three-component blends, or ablend containing more than three hydrocarbon liquids. Advantageously,in-line mixing operations (sometimes referred to as “series mixing”) mayutilize one or more controlled, tank output streams (e.g., controlledvia a low horsepower mixing booster pump and flow control valve) and agravity-fed stream, all of which are upstream of a common booster pumpused to pump a blended fluid stream through a pipeline. Further, thein-line mixing system may include sensors, disposed throughout the tankfarm, to determine density or gravity, allowing for the in-line mixingsystem to blend the hydrocarbon liquids according to a target blenddensity or gravity, providing a precisely blended fluid or liquidstream.

In some embodiments, the systems and methods as described herein mayprovide for in-line, on-demand, blending of crude oil, other hydrocarbonliquids, and/or renewable liquids at a pipeline origination station. Apipeline origination station is typically located at or near a tank farm(e.g., having a plurality of tanks containing hydrocarbon liquids). Thepipeline origination station includes extensive piping capable oftransporting the hydrocarbon liquids from each of the nearby tanks inthe tank farm to one or more mainline booster pumps, which raise thehydrocarbon liquids to very high pressures for passage through the longpipeline. A “tank farm” as used herein, refers to a plurality of tankspositioned in an area, each of the plurality of tanks configured to holdone or more hydrocarbon liquids therein. In some embodiments, theplurality of tanks may be positioned proximate to each other or theplurality of tanks may be spread out across a larger area. In someembodiments, the plurality of tanks may be positioned sequentially suchthat each tank is equally spaced apart. Generally, the number ofindividual tanks in a tank farm may vary based on the size of thepipeline origination station and/or based on the amount of hydrocarbonliquids being stored in that facility. For example, the tank farm mayinclude at least 2, at least 4, at least 6, at least 8, at least 10, atleast 12, or more individual tanks within the tank farm.

As noted above, typical pipeline origination stations require blendingof two or more different hydrocarbon liquids in a blending tank prior topumping the blended hydrocarbon liquids from the blending tank itself.However, the systems and methods of this disclosure advantageouslyprovide in-line, on-demand mixing directly in a pipe in the tank farmprior to the blended liquid being pumped to the pipeline. Such pipeblending may eliminate stratification of mixed oil in tanks and does notrequire the use of individual tank mixers in each of the tanks. Thesesystems and methods may also eliminate the need to mix the hydrocarbonliquids in one or more tanks before the hydrocarbon liquids are pumpedtherefrom, which advantageously allows for the changing of the blendon-demand and on-demand blending during operation of the pipelineorigination station. In some embodiments, for example, a separateblending tank in the tank farm is not necessary, and thus, one or moretanks in the tank farm previously used for blending may beneficially beused for storage of additional hydrocarbon liquids, which may also beblended in-line. Further, basing blending operations on gravitymeasurements may increase accuracy and precision of blending. While ablending operation constantly or continuously checking gravity andadjusting may produce a less accurate blend, due to the lagging natureof gravity adjustments versus flow rate, checking the gravity andadjusting flow rates at specified time intervals (for example, 10 to 20minute intervals) may allow for an accurate and precise blend. Further,adjusting while continuing a blending operation or process ensures anaccurate and precise blend, as well as a blend produced in the sameamount of time as a typical blending operation. Further still, suchgravity measuring and adjusting systems may include little additionalequipment (e.g., flow meters included in the tank farm may be Coriolismeters or density or gravity sensors may be added near the meter or to apipe or tank).

Other typical pipeline origination stations may use parallel mixing oftwo or more hydrocarbon liquids, which may be expensive and of lowerefficiency. In particular, typical parallel mixing operations require adedicated high horsepower mixing booster pump (e.g., greater than 750hp, greater than 850 hp, greater than 950 hp or even greater than 1,050hp) for each of the mixing streams and an additional static mixer toblend the hydrocarbon liquids pumped through each of the mixing streams.However, the systems and methods of this disclosure advantageouslyprovide cost and energy savings, because such systems and methods do notrequire high horsepower mixing booster pumps or the additional staticmixer. For example, the mixing booster pumps typically used in themixing streams of the systems and methods described herein typicallyhave lower horsepower ratings (e.g., less than 250 hp, less than 200 hp,less than 150 hp, or even less than 100 hp). In addition, the in-linemixing systems, according to this disclosure, may eliminate the need fortwo or more variable speed pumps and/or control valves (i.e., one foreach of the streams), because as further disclosed herein, one streammay be gravity-fed from the tank and thus controls itself in physicalresponse to the other controlled, tank output stream(s). Further,in-line mixing systems as described herein may provide for more accuratecontrol of blended hydrocarbon liquids, for example, within 1.0 percentor less of the desired set point (e.g., desired flow rate and/or densityor gravity) for the blended fluid flow.

FIG. 1 depicts a process diagram of a non-limiting, two-componentin-line mixing system according to one or more embodiments of thedisclosure. In particular, FIG. 1 illustrates a two component in-linemixing system 100 positioned at a tank farm (e.g., as depicted by thedashed rectangular box in FIG. 1) to admix two hydrocarbon liquids fromseparate tanks into a single pipeline to provide a two-component blendedfluid flow. As shown in FIG. 1, the two-component in-line mixing systemincludes a first tank 102 (e.g., tank A) positioned in a tank farm andcontaining a first fluid therein. Generally, the first fluid includesone or more hydrocarbon liquids, of a first density or gravity, asdefined herein above and as would be understood by a person of skill inthe art. In some embodiments, the first tank 102 may have a first outputpipe 104 connected to the first tank 102 proximate a bottom portionthereof and the first output pipe 104 may be in fluid communication withthe first fluid to transport a flow of the first fluid from the firsttank 102 through the first output pipe 104 at a first pressure. In someembodiments, the first pressure may be in the range of about 0.1 poundper square inch (psi) to about 100 psi, about 0.5 psi to about 50 psi,or about 1 psi to about 10 psi. In some embodiments, the first pressuremay be less than about 20 psi, less than about 10 psi, less than about 5psi, or less than about 1 psi. In some embodiments, the first pressureresults from force of gravity on the first fluid contained in the firsttank. For example, gravity rather than a pump transports the flow of thefirst fluid from the first tank and through the first outlet pipe. Anoutlet pipe having a pressure that results from force of gravity, andnot by a pump, may be referred to herein as a “gravity-fed” line.

In one or more embodiments, the two-component in-line mixing system mayinclude a second tank 106 (e.g., tank C) positioned in the tank farm andcontaining a second fluid therein. Generally, the second fluid includesone or more hydrocarbon liquids, of a second density or gravity, asdefined herein above and as would be understood by a person of skill inthe art. In some embodiments, the second tank 106 may have a secondoutput pipe 108 connected to the second tank 106 proximate a bottomportion thereof and the second output pipe 108 may be in fluidcommunication with the second fluid to transport a flow of the secondfluid from the second tank 106 through the second output pipe 108 at asecond pressure. In some embodiments, the second pressure may be in therange of about 0.1 pound per square inch (psi) to about 100 psi, about0.5 psi to about 50 psi, or about 1 psi to about 10 psi. In someembodiments, the second pressure may be less than about 20 psi, lessthan about 10 psi, less than about 5 psi, or less than about 1 psi.Similar to the first pressure, the second pressure also results fromforce of gravity on the second fluid contained in the second tank. Forexample, gravity rather than a pump transports the flow of the secondfluid from the second tank and through the second outlet pipe.

In one or more embodiments, two-component in-line mixing systems asdescribed herein may include a first pump 110 having an inlet and anoutlet. For example, the inlet of the first pump 110 may be connected tothe second output pipe 108 to increase pressure of the flow of thesecond fluid from the second pressure to a pump pressure at the outlet.In some embodiments, the pump pressure at the outlet of the first pumpmay be in the range of about 1 psi to about 100 psi, about 10 psi toabout 50 psi, or about 25 psi to about 35 psi. In some embodiments, thepump pressure at the outlet of the first pump may be at least about 10psi, at least about 20 psi, at least about 30 psi, at least about 40psi, at least about 50 psi, or higher. Further, this first pump 110 mayhave a horsepower between 1 hp and 500 hp, between 50 and 250 hp orbetween 125 hp and 175 hp. In such embodiments, the first pump 110 mayhave a horsepower of 500 hp or less, 400 hp or less, 300 hp or less, 200hp or less, 100 hp or less, and lower. Generally, the pump pressure atthe outlet of the first pump is greater than the second pressure in thesecond output pipe. In some embodiments, in-line mixing systems asdescribed herein may include a variable speed drive (VFD) 132 connectedto the first pump 110 to control pump speed to thereby adjust the flowof the second fluid through the first pump. Generally, variable speeddrives, which may also be referred to as adjustable speed drives, aredevices that may vary the speed of a normally fixed speed motor and/orpump based on feedback from one or more control components. The specifictype of variable speed drive may vary as would be understood by a personof skill in the art.

As depicted in FIG. 1, in some embodiments, two-component in-line mixingsystems as described herein may include a mixing booster pipe 112connected to the outlet of the first pump 110 to transport the flow ofthe second fluid therethrough. In some embodiments, a blended fluid pipe114 may be connected to and in fluid communication with the first outputpipe 104 and the mixing booster pipe 112 to admix the flow of firstfluid at the first pressure and the flow of second fluid into a blendedfluid flow. In one or more embodiments, the pump pressure of the secondfluid may be about equal to pressure of the first fluid at the portionof the blended fluid pipe 114 configured to admix the flow of firstfluid and the flow of second fluid into a blended fluid flow. In someembodiments, a tank flow meter 116 may be connected to the mixingbooster pipe 112 and positioned between the first pump 110 and theblended fluid pipe 114 to measure flow rate of the flow of the secondfluid between the first pump 110 and the blended fluid pipe 114. Thetank flow meter 116 may be a turbine flow meter or another type of flowmeter as would be known to those skilled in the art. Generally, the tankflow meter may provide flow readings in the form of barrels per hour ofhydrocarbon liquids. In another embodiment the tank flow meter 116 mayinclude a sensor or functionality to measure a density or gravity of theliquid (e.g., a mass flow meter or other meter as will be understood bythose skilled in the art). In certain embodiments, a flow control valve118 may also be connected to the mixing booster pipe 112 between thetank flow meter 116 and the blended fluid pipe 114 to control flow ofthe second fluid between the first pump 110 and the blended fluid pipe114. In some embodiments, a pressure sensor/transducer 130 may also beconnected to the mixing booster pipe 112 and positioned upstream of theflow control valve 118. In some embodiments, for example, the pressuresensor/transducer 130 may be connected to the mixing booster pipe 112proximate the tank flow meter 116. The pressure sensor/transducer 130may be configured to measure the back pressure at the flow controlvalve. Any type of pressure sensor/transducer may be used to measure theback pressure at the flow control valve as would be understood by aperson of skill in the art.

In one or more embodiments, two-component in-line mixing systems asdescribed herein may include a second pump 120 having an inlet in fluidcommunication with the blended fluid pipe 114 and an outlet. Generally,the second pump 120 will have a greater horsepower than the first pump110 and thus, the pump pressure at the outlet of the second pump may begreater than the pump pressure at the outlet of the first pump as notedabove. In some embodiments, for example, the pump pressure at the outletof the second pump may be in the range of about 50 psi to about 500 psi,about 100 psi to about 300 psi, or about 150 psi to about 200 psi. Insome embodiments, the pump pressure at the outlet of the second pump maybe at least about 50 psi, at least about 100 psi, at least about 150psi, at least about 200 psi, or higher. Further, this second pump 120may have a horsepower between 250 hp and 2,500 hp, between 500 and 2,000hp or between 750 hp and 1,500 hp. In such embodiments, the second pump120 may have a horsepower of as much as 250 hp, 500 hp, 750 hp, 1,000hp, 1,250 hp, 1,500 hp or more. The second pump 120 is positionedrelative to the first pump 110 and the first tank 102 such that thepressure in the blended fluid pipe 114 at the inlet or suction of thesecond pump 120 is sufficiently high to preclude cavitation within thesecond pump 120. Generally, the pump pressure at the outlet of thesecond pump 120 is considerably higher than the pressure at the outletof the first pump 110 to ramp up the pressure of the blended fluid flowprior to transfer to the pipeline.

In some embodiments, two-component in-line mixing systems as describedherein may include a booster flow meter 122 in fluid communication withthe blended fluid pipe 114 to measure total flow rate of the blendedfluid flow transported through the blended fluid pipe 114. The boosterflow meter 122 may be a turbine flow meter or another type of flow meteras would be known to those skilled in the art. Generally, the boosterflow meter 122 may provide flow readings in the form of barrels per hourof hydrocarbon liquids. In another embodiment the booster flow meter 122may include a sensor or functionality to measure a density or gravity ofthe blended fluid or liquid (e.g., a mass flow meter or other meter aswill be understood by those skilled in the art). In some embodiments,the in-line mixing systems as described herein may include a pipeline124 connected to the outlet of the second pump 120 to transport theblended fluid flow therethrough and away from the tank farm, e.g., to apipeline origination station. In one or more embodiments, the in-linemixing systems described herein and shown in FIG. 1, may optionallyinclude a third pump 126 positioned between the outlet of the secondpump 120 and the pipeline 124. The third pump 126 is thus arranged to bein fluid communication with the outlet of the second pump 120, thebooster flow meter 122, and the pipeline 124. Generally, the third pump126 will have a greater horsepower and a greater outlet pump pressurethan either of the first pump 110 and the second pump 120 in order totransport the blended fluid flow at much higher pressures through thepipeline 124. Such higher pressures are generally required for pumpingthe blended fluid flow along long pipelines before reaching a finaldestination. For example, such pipelines may be in excess of hundreds ofmiles in length. In some embodiments, the pump pressure at the outlet ofthe optional third pump may be in the range of about 100 psi to about10,000 psi, about 500 psi to about 5,000 psi, or about 1,000 psi toabout 2,000 psi. In some embodiments, the pump pressure at the outlet ofthe third pump 126 may be at least about 500 psi, at least about 1,000psi, at least about 1,500 psi, or higher. Further, this third pump 126may have a horsepower between 1,000 hp and 5,000 hp, between 2,000 and4,500 hp or between 3,000 hp and 4,000 hp. In such embodiments, thethird pump 126 may have a horsepower of as much as 2,500 hp, 3,000 hp,3,500 hp, 4,500 hp, 5,000 hp or more. While the third pump 126 is shownin FIG. 1 as being within the tank farm (e.g. as depicted by the dashedrectangular box in FIG. 1), the third pump 126 (and start of thepipeline 124) may be located a distance apart from the tank farm, e.g.,less than one mile, less than two or less than three miles. However, thethird pump 126 is positioned relative to the second pump 120 such thatthe pressure at the inlet or suction of the third pump 126 issufficiently high to preclude cavitation within the third pump 126.

In one or more embodiments, in-line mixing systems as described hereinmay include one or more controllers 128 in communication with the tankflow meter 116, the booster flow meter 122, the pressuresensor/transducer 130, and the variable speed drive (VFD) 132.Generally, the one or more controllers 128 may perform a variety offunctions (e.g., determining mix ratios, flow rates, various densities,various gravities, corrected mix ratios, and/or controlling one or morefunctions of various components within the in-line mixing system 100).In some embodiments, the one or more controllers 128 may be configuredto determine a ratio of the flow of second fluid to the flow of firstfluid responsive to one or more signals received from the tank flowmeter 116 and the booster flow meter 122. For example, the booster flowmeter 122 may be configured to measure a total flow rate of the blendedfluid flow therethrough and the tank flow meter 116 may be configured tomeasure the flow rate of the flow of the second fluid therethrough, suchthat the difference in the total flow rate of the blended fluid flow andthe flow rate of the flow of the second fluid is approximately equal tothe flow rate of the flow of the first fluid (e.g., which isgravity-fed). In some embodiments, both of the tank flow meter 116 andthe booster flow meter 122 may provide flow readings in units of barrelsper hour of hydrocarbon liquids. For example, if the booster flow meter122 indicates that the blended flow has a flow rate of 10,000 barrelsper hour and the tank flow meter 116 indicates that the flow rate of theflow of the second fluid is 4,000 barrels per hour, then the calculatedflow rate of the flow of the first liquid is 6,000 barrels per hour(e.g., providing a mix ratio in the blended flow of approximately 40:60(second fluid:first fluid)). In some embodiments, the one or morecontrollers 128 may be in communication with each of the tank flow meter116 and the booster flow meter 122 to determine flow rate of the firstfluid from the first tank 102 responsive to signals received from thetank flow meter 116 and the booster flow meter 122. In some embodiments,the tank flow meter 116 and booster flow meter 122 may include othersensors or functionality to provide a density or gravity of the secondfluid (as well as the first fluid, in another example). If provided as agravity, the tank flow meter 116 and booster flow meter 122 may indicatethe gravity as a specific gravity. The one or more controllers 128 mayfurther determine a density or gravity of the first fluid, based on thedensities or gravities of the second fluid and blended fluid. Further,the controller 128 may adjust the flow rate of second flow, based on thedensities or gravities of the first fluid, the second fluid, and theblended fluid and the target blend density or gravity.

In such embodiments, the ratio of the flow of the second fluid to theflow of the first fluid may be referred to herein as the mix ratio ofthe blended fluid flow. In some embodiments, the mix ratio may be variedin the range of about 1:99 (second fluid:first fluid) to about 99:1(second fluid:first fluid). For example, in some embodiments, theblended fluid flow may include the flow of the second fluid in an amountof at least 5 percent, at least 10 percent, at least 15 percent, atleast 20 percent, at least 25 percent, at least 30 percent, at least 35percent, at least 40 percent, at least 45 percent, at least 50 percent,at least 55 percent, at least 60 percent, at least 65 percent, at least70 percent, at least 75 percent, at least 80 percent, at least 85percent, at least 90 percent, at least 95 percent, or more. In someembodiments, the blended fluid flow may include the flow of the firstfluid in an amount of at least 5 percent, at least 10 percent, at least15 percent, at least 20 percent, at least 25 percent, at least 30percent, at least 35 percent, at least 40 percent, at least 45 percent,at least 50 percent, at least 55 percent, at least 60 percent, at least65 percent, at least 70 percent, at least 75 percent, at least 80percent, at least 85 percent, at least 90 percent, at least 95 percent,or more.

As noted above, the mix ratio (also referred to as the blend ratio)generally refers to the ratio of the second fluid to the first fluid inthe total blended fluid flow. For example, a hypothetical blended fluidflow having a total flow rate of 10,000 barrels per hour with a mixratio of 60:40 (second fluid:first fluid) would equate to a second fluidflow rate of 6,000 barrels per hour and a first fluid flow rate of 4,000barrels per hour. Thus, the actual mix ratio may be constantlycalculated during operation of the in-line mixing system based onmeasurement of the individual flow rates of the flow of the second fluidand the flow of the first fluid. It should be noted that the actual mixratio will inherently fluctuate above and below a set point in acontrolled system (e.g., such as in-line mixing systems 100 as describedherein) based on control adjustments being made on-demand, in real-time.In addition, the amount of fluctuation in the actual mix ratio (e.g.,the variance in the mix ratio) may be higher at the beginning of ablending operation run (e.g., operation for 30 minutes or less, 20minutes or less, 10 minutes or less, or 5 minutes or less after a newset point mix ratio is input into the system) relative to a later timein the same blending operation run when steady state control has beenachieved (e.g., operation for 30 minutes or longer, 1 hour or longer, 2hours or longer, 4 hours or longer, 8 hours or longer, 12 hours orlonger, or 24 hours or longer after a new set point mix ratio is inputinto the system). Generally, longer blending operation runs may providebetter accuracy because steady state is reached within the in-linemixing system and this steady state is maintained for a longer period oftime. Advantageously, the systems and methods of in-line mixing asdescribed herein provide far more accurate control of the mix ratio(both at the beginning of a blending operation run and for the durationof the blending operation run) than typically provided with otherblending methods commonly used in the art. In-line mixing systems 100according to the disclosure may maintain the mix ratio within about+/−1.0 percent of the desired/pre-selected set point mix ratio. Incertain embodiments, in-line mixing systems according to the disclosuremay maintain the mix ratio within about +/−1.0 percent, about +/−0.5percent, about +/−0.25 percent, about +/−0.1 percent, or about +/−0.05percent of the desired/pre-selected set point mix ratio.

In one or more embodiments, the one or more controllers 128 may includea programmable logic controller. The one or more controllers 128 may bein communication with the variable speed drive 132, which may beconnected to the first pump 110, and configured to control the variablespeed drive 132. In such embodiments, the one or more controllers 128may be configured to compare the mix ratio to a pre-selected set pointratio and to determine a modified flow of the second fluid, ifnecessary, to bring the mix ratio closer to the pre-selected set pointratio. For example, the one or more controllers 128 may be configured tosend a control signal to the variable speed drive 132 to control thepump speed and thereby adjust the flow of the second fluid in order todrive the mix ratio toward the pre-selected set point ratio. If the mixratio is lower than the pre-selected set point ratio, then the flow ofthe second fluid may be increased to drive the mix ratio toward thepre-selected set point ratio. Likewise, if the mix ratio is higher thanthe pre-selected set point ratio, then the flow of the second fluid maybe decreased to drive the mix ratio toward the pre-selected set pointratio.

In one or more embodiments, the one or more controllers 128, e.g., aprogrammable logic controller, may be in communication with the flowcontrol valve 118 and configured to control the flow control valve. Forexample, in some embodiments, the one or more controllers 128 may governthe flow control valve 118 to maintain pressure at the tank flow meter116 between about 15 psi and about 25 psi. In at least one embodiment,the one or more controllers 128 may be configured to compare the mixratio to a pre-selected set point ratio to determine a modified flow ofthe second fluid. In some embodiments, the one or more controllers 128may be configured to send a control signal to the flow control valve 118to control the valve setting and thereby the flow of the second fluid inorder to drive the mix ratio toward the pre-selected set point ratio. Ifthe mix ratio is lower than the pre-selected set point ratio, then theflow control valve 118 may be opened to increase the flow of the secondfluid to drive the mix ratio toward the pre-selected set point ratio.Likewise, if the mix ratio is higher than the pre-selected set pointratio, then the flow control valve 118 may be pinched to reduce the flowof the second fluid to drive the mix ratio toward the pre-selected setpoint ratio.

In one or more embodiments of in-line mixing systems 100, the variablespeed drive (VFD) 132 and the flow control valve 118 may work togetherbased on input from the one or more controllers 128, including theprogrammable logic controller. In some embodiments, for example, whenthe speed of the first pump 110 drops below 60%, the programmable logiccontroller may send a signal to pinch the flow control valve 118 (e.g.,reducing the pressure at the output of the flow control valve by about 5psi) to force the first pump 110 to increase speed to maintain the mixratio. Likewise, if the speed of the first pump 110 increases to 100%,the programmable logic controller may send a signal to the flow controlvalve 118 to open the flow control valve 118 (e.g., increasing thepressure at the output of the flow control valve by about 5 psi) toforce the first pump 110 to decrease speed to maintain the mix ratio.Generally, the pressure at the flow control valve 118 is maintained atabout 20 psi when the in-line mixing system is maintained at steadystate.

As noted above, in one or more embodiments, the system and methodsdescribed herein may provide in-line mixing of three or more componentblends in a single pipe. For example, FIGS. 2-4 depict process diagramsof non-limiting, three-component in-line mixing system according tovarious embodiments of the disclosure. In particular, FIGS. 2-4illustrate embodiments, of three-component in-line mixing systems 200positioned at a tank farm (e.g., as depicted by the dashed rectangularboxes in FIGS. 2-4) to admix three hydrocarbon liquids from separatetanks into a single pipeline to provide a two-component blended fluidflow. As shown in FIGS. 2-4, a three-component in-line mixing system mayinclude a first tank 202 positioned in a tank farm and containing afirst fluid therein. Generally, the first fluid includes one or morehydrocarbon liquids, of a first density or gravity, as defined hereinabove and as would be understood by a person of skill in the art. Insome embodiments, the first tank may include a first output pipe 204connected to the first tank 202 proximate a bottom portion thereof andthe first output pipe 204 may be in fluid communication with the firstfluid to transport a flow of the first fluid from the first tank 202through the first output pipe 204 at a first pressure. In someembodiments, the first pressure may be in the range of about 0.1 psi toabout 100 psi, about 0.5 psi to about 50 psi, or about 1 psi to about 10psi. In some embodiments, the first pressure may be less than about 20psi, less than about 10 psi, less than about 5 psi, or less than about 1psi. In the embodiments depicted in FIGS. 2-4, the first pressureresults from force of gravity on the first fluid contained in the firsttank.

In one or more embodiments, the three-component in-line mixing systemmay include a second tank 206 positioned in the tank farm and containinga second fluid therein. Generally, the second fluid includes one or morehydrocarbon liquids, of a second density or gravity, as defined hereinabove and as would be understood by a person of skill in the art. Insome embodiments, the second tank 206 may include a second output pipe208 connected to the second tank 206 proximate a bottom portion thereofand the second output pipe 208 may be in fluid communication with thesecond fluid to transport a flow of the second fluid from the secondtank 206 through the second output pipe 208 at a second pressure. Insome embodiments, the second pressure may be in the range of about 0.1psi to about 100 psi, about 0.5 psi to about 50 psi, or about 1 psi toabout 10 psi. In some embodiments, the second pressure may be less thanabout 20 psi, less than about 10 psi, less than about 5 psi, or lessthan about 1 psi. Similar to the first pressure, the second pressurealso results from force of gravity on the second fluid contained in thesecond tank 206.

In one or more embodiments, the three-component in-line mixing systemmay include a third tank 210 positioned in the tank farm and containinga third fluid therein. Generally, the third fluid includes one or morehydrocarbon liquid, of a third density or gravity, as defined hereinabove and as would be understood by a person of skill in the art. Insome embodiments, the third tank 210 may include a third output pipe 212connected to the third tank 210 proximate a bottom portion thereof andthe third output pipe 212 may be in fluid communication with the thirdfluid to transport a flow of the third fluid from the third tank 210through the third output pipe 212 at a third pressure. In someembodiments, the third pressure may be in the range of about 0.1 psi toabout 100 psi, about 0.5 psi to about 50 psi, or about 1 psi to about 10psi. In some embodiments, the second pressure may be less than about 20psi, less than about 10 psi, less than about 5 psi, or less than about 1psi. Similar to the first and second pressures, the third pressure alsoresults from the force of gravity on the third fluid contained in thethird tank 210.

In one or more embodiments, three-component in-line mixing systems 200as described herein may include a second tank pump 214 having an inletand an outlet. For example, the inlet of the second tank pump 214 may beconnected to the second output pipe 208 to increase pressure of the flowof the second fluid from the second pressure to a second pump pressureat the outlet of the second tank pump 214. In some embodiments, thesecond pump pressure at the outlet of the second tank pump 214 may be inthe range of about 1 psi to about 100 psi, about 10 psi to about 50 psi,or about 25 psi to about 35 psi. In some embodiments, the second pumppressure at the outlet of the second tank pump 214 may be at least about10 psi, at least about 20 psi, at least about 30 psi, at least about 40psi, at least about 50 psi, or higher. Further, this second tank pump214 may have a horsepower between 1 hp and 500 hp, between 50 and 250 hpor between 125 hp and 175 hp. In such embodiments, the second tank pump214 may have a horsepower of 500 hp or less, 400 hp or less, 300 hp orless, 200 hp or less, 100 hp or less, and lower. Generally, the secondpump pressure at the outlet of the second tank pump 214 is greater thanthe second pressure in the second output pipe 208. In some embodiments,a second tank mixing booster pipe 216 may be connected to the outlet ofthe second tank pump 214 to transport the flow of the second fluidtherethrough. In some embodiments, three-component in-line mixingsystems 200 as described herein may include a second variable speeddrive 244 connected to the second tank pump 214 to control pump speed tothereby adjust the flow of the second fluid through the second tank pump214. The specific type and/or configuration of the second variable speeddrive 244 may vary as would be understood by a person of skill in theart.

In one or more embodiments, three-component in-line mixing systems 200as described herein may include a third tank pump 218 having an inletand an outlet. For example, the inlet of the third tank pump 218 may beconnected to the third output pipe 212 to increase pressure of the flowof the third fluid from the third pressure to a third pump pressure atthe outlet of the third tank pump 218. In some embodiments, the thirdpump pressure at the outlet of the third tank pump 218 may be in therange of about 1 psi to about 100 psi, about 10 psi to about 50 psi, orabout 25 psi to about 35 psi. In some embodiments, the third pumppressure at the outlet of the third tank pump 218 may be at least about10 psi, at least about 20 psi, at least about 30 psi, at least about 40psi, at least about 50 psi, or higher. Further, this third tank pump 218may have a horsepower between 1 hp and 500 hp, between 50 and 250 hp orbetween 125 hp and 175 hp. In such embodiments, the third tank pump 218may have a horsepower of 500 hp or less, 400 hp or less, 300 hp or less,200 hp or less, 100 hp or less, and lower. Generally, the third pumppressure at the outlet of the third tank pump 218 is greater than thethird pressure in the third output pipe 212. In some embodiments, athird tank mixing booster pipe 220 may be connected to the outlet of thethird tank pump 218 to transport the flow of the third fluidtherethrough. In some embodiments, three-component in-line mixingsystems 200 as described herein may include a third variable speed drive248 connected to the third tank pump 218 to control pump speed tothereby adjust the flow of the third fluid through the third tank pump218. The specific type and/or configuration of the third variable speeddrive 248 may vary as would be understood by a person of skill in theart.

As depicted in FIGS. 2-4, in some embodiments, three-component in-linemixing systems 200 may include a blended fluid pipe 222 connected to andin fluid communication with the first output pipe 204, the second tankmixing booster pipe 216, and the third tank mixing booster pipe 220 toadmix the flow of the first fluid at the first pressure, the flow of thesecond fluid, and the flow of the third fluid into a blended fluid flow.In some embodiments, the pressures of the third fluid, the second fluid,and the first fluid may be about the same at the portion of the blendedfluid pipe 222 configured to admix the flow of the first fluid, the flowof the second fluid, and the flow of the third fluid into the blendedfluid flow.

As noted in FIGS. 2-4, for example, the connection point between thefirst output pipe 204, the second tank mixing booster pipe 216, thethird tank mixing booster pipe 220, and the blended fluid pipe 222 mayvary in different embodiments. As depicted in FIG. 2, for example, theblended fluid pipe 222 may be directly in line with the first outputpipe 204 (i.e., the gravity fed output line) with the second tank mixingbooster pipe 216 and the third tank mixing booster pipe 220, or acombined pipe thereof, flowing into first output pipe/blended fluid pipejunction, e.g., through a tee joint or y joint. As depicted in FIG. 3,the blended fluid pipe 222 may be directly in line with the second tankmixing booster pipe 216 or, in another example, the third tank mixingbooster pipe 220 such that the first output pipe 204 is routed to flowinto the junction between the blended fluid pipe and the second tankmixing booster pipe 216 and/or third tank mixing booster pipe 220, e.g.,through a tee joint, y joint, or four-way joint. Further, as depicted inFIG. 4, any one of the plurality of tanks in the tank farm may beconfigurable to be a gravity fed line (e.g., such as the first outputpipe 204 in FIG. 2) or to be a controlled, tank output stream (e.g.,such as the second tank mixing booster pipe 216 or the third tank mixingbooster pipe 220 in FIG. 2). For example, the first tank 202 may beconfigured to be the gravity fed line or the third tank 210 may,instead, be configured as the gravity fed line. Likewise, the first tank202 or the third tank 210 may be configured to be a controlled, tankoutput stream. Such configurations and arrangements are not intended tobe limiting and are presented by way of example only. Generally, theconfiguration and/or arrangement of the first output pipe, the secondtank mixing booster pipe, the third tank mixing booster pipe, and theblended fluid pipe may vary based on the configuration of the tank farm.

Referring again to FIGS. 2-4, in some embodiments of three-componentin-line mixing systems 200 as described herein, a second tank flow meter224 may be connected to the second tank mixing booster pipe 216 andpositioned between the second tank pump 214 and the blended fluid pipe222 to measure flow rate of the flow of the second fluid between thesecond tank pump 214 and the blended fluid pipe 222. The second tankflow meter 224 may be a turbine flow meter or another type of flow meteras would be known to those skilled in the art. Generally, the boosterflow meter 234 may provide flow readings in the form of barrels per hourof hydrocarbon liquids. In another embodiment, the second tank flowmeter 224 may include a sensor or functionality to measure a density orgravity of the blended fluid or liquid (e.g., a mass flow meter or othermeter as will be understood by those skilled in the art). In someembodiments, a second tank flow control valve 226 may be connected tothe second tank mixing booster pipe 216 between the second tank flowmeter 224 and the blended fluid pipe 222 to control the flow of thesecond fluid between the second tank pump 214 and the blended fluid pipe222. In some embodiments, a second tank pressure sensor/transducer 242may also be connected to the second tank mixing booster pipe 216 andpositioned upstream of the second tank flow control valve 226. In someembodiments, for example, the second tank pressure sensor/transducer 242may be connected to the second tank mixing booster pipe 216 between thesecond tank flow meter 224 and the second tank flow control valve 226.The second tank pressure sensor/transducer 242 may be configured tomeasure the back pressure at the second tank flow control valve 226. Anytype of pressure sensor/transducer may be used to measure the backpressure at the second tank flow control valve 226 as would beunderstood by a person of skill in the art.

In some embodiments, three-component in-line mixing systems 200 asdescribed herein may include a third tank flow meter 228 connected tothe third tank mixing booster pipe 220 and positioned between the thirdtank pump 218 and the blended fluid pipe 222 to measure flow rate of theflow of the third fluid between the third tank pump 218 and the blendedfluid pipe 222. The third tank flow meter 228 may be a turbine flowmeter or another type of flow meter as would be known to those skilledin the art. Generally, the third tank flow meter 228 may provide flowreadings in the form of barrels per hour of hydrocarbon liquids. Inanother embodiment the third tank flow meter 228 may include a sensor orfunctionality to measure a density or gravity of the blended fluid orliquid (e.g., a mass flow meter or other meter as will be understood bythose skilled in the art). In some embodiments, a third tank flowcontrol valve 230 may be connected to the third tank mixing booster pipe220 between the third tank flow meter 228 and the blended fluid pipe 222to control the flow of the third fluid between the third tank pump 218and the blended fluid pipe 222. In some embodiments, a third tankpressure sensor/transducer 246 may also be connected to the third tankmixing booster pipe 220 and positioned upstream of the third tank flowcontrol valve 230. In some embodiments, for example, the third tankpressure sensor/transducer 246 may be connected to the third tank mixingbooster pipe 220 between the third tank flow meter 228 and the thirdtank flow control valve 230. The third tank pressure sensor/transducer246 may be configured to measure the back pressure at the third tankflow control valve 230. Any type of pressure sensor/transducer may beused to measure the back pressure at the third tank flow control valve230 as would be understood by a person of skill in the art.

In one or more embodiments, three-component in-line mixing systems 200and methods may include a booster pump 232 having an inlet in fluidcommunication with the blended fluid pipe 222 and an outlet. Generally,the booster pump 232 will have a greater horsepower than the second tankpump 214 and the third tank pump 218 and thus, the pump pressure at theoutlet of the booster pump 232 may be greater than the pump pressure atthe outlet of the second tank pump 214 and/or the third tank pump 218.In some embodiments, for example, the pump pressure at the outlet of thebooster pump 232 may be in the range of about 50 psi to about 500 psi,about 100 psi to about 300 psi, or about 150 psi to about 200 psi. Insome embodiments, the pump pressure at the outlet of the booster pump232 may be at least about 50 psi, at least about 100 psi, at least about150 psi, at least about 200 psi, or higher. Further, the booster pump232 may have a horsepower between 250 hp and 2,500 hp, between 500 and2,000 hp or between 750 hp and 1,500 hp. In such embodiments, thebooster pump 232 may have a horsepower of as much as 250 hp, 500 hp, 750hp, 1,000 hp, 1,250 hp, 1,500 hp or more. The booster pump 232 ispositioned relative to the second tank pump 214, the third tank pump 218and the first tank 202 such that the pressure in the blended fluid pipe222 at the inlet or suction of the booster pump 232 is sufficiently highto preclude cavitation within the booster pump 232. Generally, the pumppressure at the outlet of the booster pump 232 is considerably higherthan the pressure at the outlet of the second tank pump 214 and/or thethird tank pump 218 to ramp up the pressure of the blended fluid flowprior to transfer to the pipeline 236.

In some embodiments, three-component in-line mixing systems 200 asdescribed herein may include a booster flow meter 234 in fluidcommunication with the blended fluid pipe 222 to measure total flow rateof the blended fluid flow transported through the blended fluid pipe222. The booster flow meter 234 may be a turbine flow meter or anothertype of flow meter as would be known to those skilled in the art.Generally, the booster flow meter may provide flow readings in the formof barrels per hour of hydrocarbon liquids. In some embodiments, thethree-component in-line mixing systems 200 as described herein mayinclude a pipeline 236 connected to the outlet of the booster pump 232to transport the blended fluid flow therethrough and away from the tankfarm, e.g., to a pipeline origination station. In one or moreembodiments, the three-component in-line mixing systems 200 describedherein, and as shown in FIGS. 2-4, may include a pipeline originationstation pump 238 positioned between the outlet of the booster pump 232and the pipeline 236. The pipeline origination station pump 238 isarranged to be in fluid communication with the outlet of the boosterpump 232, the booster flow meter 234 and the pipeline 236. Generally,the pipeline origination station pump 238 may have a greater horsepowerand a greater outlet pump pressure than each of the second tank pump214, the third tank pump 218, and the booster pump 232 in order totransport the blended fluid flow at much higher pressures through thepipeline 236. Such higher pressures are generally required for pumpingthe blended fluid flow through long pipelines before reaching a finaldestination. For example, such pipelines may be in excess of hundreds ofmiles in length. In some embodiments, the pump pressure at the outlet ofthe pipeline origination station pump 238 may be in the range of about100 psi to about 10,000 psi, about 500 psi to about 5,000 psi, or about1,000 psi to about 2,000 psi. In some embodiments, the pump pressure atthe outlet of the second tank pump 214 and/or third tank pump 218 may beat least about 500 psi, at least about 1,000 psi, at least about 1,500psi, or higher. Further, the pipeline origination station pump 238 mayhave a horsepower between 1,000 hp and 5,000 hp, between 2,000 and 4,500hp or between 3,000 hp and 4,000 hp. In such embodiments, the pipelineorigination station pump 238 may have a horsepower of as much as 2,500hp, 3,000 hp, 3,500 hp, 4,500 hp, 5,000 hp or more. While the pipelineorigination station pump 238 is shown in FIGS. 2-4 as being within thetank farm (e.g. as depicted by the dashed rectangular box in FIGS. 2-4),the pipeline origination station pump 238 (and start of the pipeline236) may be located a distance apart from the tank farm, e.g., less thanone mile, less than two or less than three miles. However, the pipelineorigination station pump 238 may be positioned relative to the boosterpump 232 such that the pressure at the inlet or suction of the pipelineorigination station pump 238 is sufficiently high to preclude cavitationwithin the pipeline origination station pump 238.

In one or more embodiments, three-component in-line mixing systems 200as described herein may include one or more controllers 240 incommunication with the second tank flow meter 224, the third tank flowmeter 228, the booster flow meter 234, the second tank pressuresensor/transducer 242, the second variable speed drive 244, the thirdtank pressure sensor/transducer 246, and the third variable speed drive248. Generally, the one or more controllers 240 may perform a variety offunctions (e.g., determining mix ratios, flow rates, various densities,various gravities, corrected mix ratios, and/or controlling one or morefunctions of various components within the system). In some embodiments,the one or more controllers 240 may be configured to determinepercentages of the first fluid flow rate, the second fluid flow rate,and the third fluid flow rate in the total blended flow responsive toone or more signals received from the second tank flow meter 224, thethird tank flow meter 228, and the booster flow meter 234. For example,the booster flow meter 234 may be configured to measure a total flowrate of the blended fluid flow therethrough; the second tank flow meter224 may be configured to measure the flow rate of the flow of the secondfluid therethrough; and the third tank flow meter 228 may be configuredto measure the flow rate of the flow of the third fluid therethrough,such that the difference in the total flow rate of the blended fluidflow, the flow rate of the flow of the second fluid, and the flow rateof the flow of the third fluid is approximately equal to the flow rateof the flow of the first fluid (e.g., which is gravity-fed). In someembodiments, each of the second tank flow meter 224, the third tank flowmeter 228 and the booster flow meter 234 may provide flow readings inunits of barrels per hour of hydrocarbon liquids. For example, if thebooster flow meter 234 indicates that the blended fluid flow has a flowrate of 10,000 barrels per hour and the second tank flow meter 224indicates that the flow rate of second fluid flow is 4,000 barrels perhour and the third tank flow meter 228 indicates that the flow rate ofthe third fluid flow is 5,000 barrels per hour, then the calculated flowrate of the first fluid flow is 1,000 barrels per hour (e.g., providingmix percentages in the blended flow of 50/40/10 (third fluid:secondfluid:first fluid)). In some embodiments, the one or more controllers240 may be in communication with each of the second tank flow meter 224,the third tank flow meter 228, and the booster flow meter 234 todetermine flow rate of the first fluid from the first tank 202responsive to signals received from the second tank flow meter 224,third tank flow meter 228, and the booster flow meter 234.

In some embodiments, the percentages of the third fluid flow to thesecond fluid flow to the first fluid flow may be referred to herein asthe mix percentages of the blended fluid flow. In some embodiments, themix percentages may be varied in the range of about 1 percent to about98 percent for each of the first fluid flow, the second fluid flow, andthe third fluid flow. For example, in some embodiments, the blendedfluid flow may include the first fluid flow in an amount of at least 5percent, at least 10 percent, at least 15 percent, at least 20 percent,at least 25 percent, at least 30 percent, at least 35 percent, at least40 percent, at least 45 percent, at least 50 percent, at least 55percent, at least 60 percent, at least 65 percent, at least 70 percent,at least 75 percent, at least 80 percent, at least 85 percent, at least90 percent, at least 95 percent, or more. In some embodiments, theblended fluid flow may include the second fluid flow in an amount of atleast 5 percent, at least 10 percent, at least 15 percent, at least 20percent, at least 25 percent, at least 30 percent, at least 35 percent,at least 40 percent, at least 45 percent, at least 50 percent, at least55 percent, at least 60 percent, at least 65 percent, at least 70percent, at least 75 percent, at least 80 percent, at least 85 percent,at least 90 percent, at least 95 percent, or more. In some embodiments,the blended fluid flow may include the third fluid flow in an amount ofat least 5 percent, at least 10 percent, at least 15 percent, at least20 percent, at least 25 percent, at least 30 percent, at least 35percent, at least 40 percent, at least 45 percent, at least 50 percent,at least 55 percent, at least 60 percent, at least 65 percent, at least70 percent, at least 75 percent, at least 80 percent, at least 85percent, at least 90 percent, at least 95 percent, or more. In someembodiments, the percentages of the third fluid flow to the second fluidflow to the first fluid flow may be referred to in terms of a percentagemix ratio. For example, in some embodiments, the percentage mix ratiomay be about 50:49:1 (third fluid:second fluid:first fluid). In otherembodiments, the percentage mix ratio may be about 50:46:4 (thirdfluid:second fluid:first fluid). Generally, the percentage mix ratio maybe varied such that any of the fluid flows are provided in amountbetween about 1 percent and about 98 percent of the total blended flow.

Advantageously, the systems and methods of in-line mixing as describedherein provide far more accurate control of the mix ratio (both at thebeginning of a blending operation run and for the duration of theblending operation run) than typically provided with other blendingmethods commonly used in the art. For example, in-line mixing systemsand methods according to the disclosure may maintain the mix percentageswithin about +/−1.0 percent of the desired/pre-selected set pointpercentages. In some embodiments, in-line mixing systems and methodsaccording to the disclosure may maintain the mix percentages withinabout +/−1.0 percent, about +/−0.5 percent, about +/−0.25 percent, about+/−0.1 percent, or about +/−0.05 percent of the desired/pre-selected setpoint percentages.

In at least one embodiment, the one or more controllers 240 may includea programmable logic controller. The one or more controllers 240 may bein communication with one or more variable speed drives (e.g., connectedto the second tank pump 214 and/or to the third tank pump 218) andconfigured to control the variable speed drives. In some embodiments,for example, in-line mixing systems and methods of the disclosure mayinclude a second variable speed drive 244 connected to the second tankpump 214 and a third variable speed drive 248 connected to the thirdtank pump 218. In such embodiments, the one or more controllers 240 maybe configured to compare the mix percentages to a pre-selected set pointpercentages and to determine a modified flow of one or both of thesecond fluid flow and the third fluid flow, if necessary, to bring themix percentages closer to the pre-selected set point percentages. Forexample, the one or more controllers 240 may be configured to send acontrol signal to at least one of the second variable speed drive 244and the third variable speed drive 248 to control the pump speed of thesecond tank pump 214 and/or third tank pump 218, respectively, andthereby adjust the flow of at least one of the second fluid and thethird fluid in order to drive the mix percentages toward thepre-selected set point percentages.

In one or more embodiments, the one or more controllers 240 may be incommunication with second tank flow meter 224, third tank flow meter228, and booster flow meter 234. The one or more controllers 240 mayobtain or determine a density or gravity for each liquid flowing throughsecond tank flow meter 224, third tank flow meter 228, and booster flowmeter 234. In such examples, the one or more controllers 240 may includea target blend density or gravity or a preset blend density or gravity.Such a target blend density or gravity may indicate the desired ortarget density or gravity of the blended fluid. As is illustrated inFIGS. 2-4, a meter may not be associated with the first tank 202. Inother words, the density or gravity may not be measured for the firsttank 202. Further, the one or more controllers 240 may determine thefirst density or gravity of the first liquid, based on the seconddensity or gravity (obtained or determined via second tank flow meter224), the third density or gravity (obtained or determined via thirdtank flow meter 228), and the blend density or gravity (obtained ordetermined via booster flow meter 234). Once all densities or gravitiesare available, the one or more controllers 240 may compare the blenddensity or gravity with the target blend density or gravity. Based ondifferences of such comparisons, the one or more controllers 240 maydetermine a corrected mix ratio. The one or more controllers 240 mayadjust the flow, based on the corrected mix ratio, of at least one ofthe second fluid and the third fluid, via the second variable speeddrive 244 and the third variable speed drive 248 and/or second tank flowcontrol valve 226 and the third tank flow control valve 230, in order todrive the blend density or gravity toward the target or preset blenddensity or gravity.

In one or more embodiments, the one or more controllers 240, e.g., aprogrammable logic controller, may be in communication with one or bothof the second tank flow control valve 226 and the third tank flowcontrol valve 230, and configured to control one or both of the secondtank flow control valve 226 and the third tank flow control valve 230.For example, in some embodiments, the one or more controllers 240 maygovern the second tank flow control valve 226 and the third tank flowcontrol valve 230 to maintain pressure at each of the second tank flowmeter 224 and the third tank flow meter 228 between about 15 psi andabout 25 psi. In at least one embodiment, the one or more controllers240 may be configured to compare the mix percentages to pre-selected setpoint percentages to determine a modified flow of one or both of thesecond fluid and the third fluid. In some embodiments, the one or morecontrollers 240 may be configured to send a control signal to at leastone of the second tank flow control valve 226 and the third tank flowcontrol valve 230 to control the respective valve setting and therebythe flow of second fluid and third fluid, respectively, in order todrive the mix percentages toward the pre-selected set point percentages.

In one or more embodiments of in-line mixing systems, the secondvariable speed drive 244 and the second tank flow control valve 226 maywork together based on input from the one or more controllers 240,including the programmable logic controller. In some embodiments, thethird variable speed drive 248 and the third tank flow control valve 230may work together based on input from the one or more controllers 240,including the programmable logic controller. In some embodiments, forexample, when the speed of the second tank pump 214 and/or the thirdtank pump 218 drops below 60%, the programmable logic controller maysend a signal to pinch the second tank flow control valve 226 and/or thethird tank flow control valve 230 (e.g., reducing the pressure at theoutput of the flow control valve by about 5 psi), respectively, to forcethe second tank pump and/or the third tank pump to increase speed tomaintain the desired mix percentages. Likewise, if the speed of thesecond tank pump 214 and/or the third tank pump 218 increases to 100%,the programmable logic controller may send a signal to open the secondtank flow control valve 226 and/or the third tank flow control valve 230(e.g., increasing the pressure at the output of the flow control valveby about 5 psi), respectively, to force the second tank pump 214 and/orthe third tank pump 218 to decrease speed to maintain the desired mixpercentages. Generally, the pressure at both the second tank flowcontrol valve 226 and the third tank flow control valve 230 ismaintained at about 20 psi when the in-line mixing system is maintainedat steady state.

FIG. 5 depicts a process diagram of a controlled, tank output stream 300having a recirculation loop, the controlled output stream includes arecirculation pipe 302, and a one-way valve 304 disposed in therecirculation pipe, a mixing booster pipe 306, a pump 308, an outputpipe 310, a tank flow meter 312, and a flow control valve 314. Asdepicted in FIG. 5, the controlled, tank output stream line may includean end portion 302 a of a recirculation pipe 302 connected to and influid communication with a mixing booster pipe 306 downstream of a pump308 and another end portion 302B of the recirculation pipe 302 connectedto and in fluid communication with an output pipe 310. Thus, therecirculation pipe 302 is arranged to recirculate a fluid therethroughin order to maintain a minimum flow of the fluid through the pump 308.In some embodiments, the recirculation loop may include a one-way valve304 disposed in the recirculation pipe 302 to prevent flow of the fluidfrom the output pipe to the mixing booster pipe 306.

A recirculation loop as depicted in FIG. 5 (e.g., including arecirculation pipe 302 and a one-way valve 304 disposed in therecirculation pipe 302) may be used in combination with any of thecontrolled, tank output streams in the systems described herein above(e.g., such as those depicted in FIGS. 1-4). In such embodiments, therecirculation pipe 302 may be positioned proximate to the pump 308connected to the tank output pipe in the controlled, tank output streams(e.g., such as the second output pipe 108 in FIG. 1 and/or the secondoutput pipe 208 in FIGS. 2-4 and/or the third output pipe 212 in FIGS.2-4). In FIG. 1, for example, a recirculation pipe 302 and a one-wayvalve 304 disposed in the recirculation pipe 302 may be positionedproximate to first pump 110 to provide a recirculation system having thesame components depicted in FIG. 5. In such embodiments, therecirculation pipe 302 may be configured to permit flow therethroughonly when a ratio of the flow of second fluid to the flow of first fluidfalls below a pre-selected threshold. In FIGS. 2-4, for example, arecirculation pipe 302 and a one-way valve 304 disposed in therecirculation pipe 302 may be positioned proximate one or both of secondtank pump 214 and third tank pump 218 to provide a recirculation systemhaving the same components depicted in FIG. 5. In such embodiments, therecirculation pipe 302 may be configured to permit flow therethroughwhen the flow of the second fluid is below a pre-selected percentage(e.g., when the recirculation pipe 302 is positioned proximate secondpump tank 214) and/or configured to permit flow therethrough when theflow of the third fluid is below a pre-selected percentage (e.g., whenthe recirculation pipe 302 is positioned proximate third pump tank 218).

In one or more embodiments, in-line mixing systems and methods accordingto the disclosure may include a recirculation loop in each of thecontrolled, tank output streams. In such embodiments, the one-way valve304 disposed in the recirculation pipe 302 may be in communication withone or more control components as described herein above. In someembodiments, if the flow control valve 314 holds a back pressure thatexceeds a pre-selected setting (as determined by a pressuresensor/transducer 316 positioned upstream of the flow control valve 314)and the pump 308 falls at or below 60 percent operational capacity orthroughput, the one or more controllers will send a signal to theone-way valve 304 to open the one-way valve 304. The pump 308 then pumpsfluid through the recirculation pipe 302 via the open one-way valve 304and back to the suction inlet of the pump 308, which increases fluidflow through the pump 308. Accordingly, the pump 308 is permitted tooperate at greater than 60% throughout even while the flow control valve314 holds a back pressure exceeding the pre-selected setting. Once theback pressure drops below a pre-selected value (as determined by thepressure sensor/transducer 316 positioned upstream of the valve), whichcorresponds to the valve opening to permit greater fluid flowtherethrough, the one or more controllers will send a signal to theone-way valve to close. Advantageously, these three components (i.e.,the variable speed pump, the flow control valve, and the recirculationloop) may work together to prevent damage (e.g., cavitation) to the pumpby maintaining an acceptable flow rate through the pump at all times.

Some aspects of the disclosure relate to methods of admixing hydrocarbonliquids (such as those described herein above) from a plurality of tanksinto a single pipeline, e.g., using one or more system embodimentsherein, to provide in-line mixing thereof. As noted herein above, thesystems and methods described herein are intended to be suitable forproviding mixing of two or more hydrocarbon liquids in-line, e.g., toprovide two-component blended flows, three-component blended flows, orblended flows having more than three components.

In one or more embodiments, for example, methods for admixing twohydrocarbon liquids from a plurality of tanks into a single pipeline mayinclude determining a ratio of a second fluid flow to a first fluid flowbased on signals received from a tank flow meter in fluid communicationwith the second fluid flow and a booster flow meter in fluidcommunication with a blended fluid flow. In such embodiments, theblended fluid flow may include a blended flow of the first fluid flowand the second fluid flow. In one or more embodiments, the methodsdescribed herein may include comparing the determined ratio to apre-selected set point ratio to thereby determine a modified flow of thesecond fluid flow in order to drive the ratio toward the pre-selectedset point ratio. In some embodiments, the methods described herein mayinclude controlling a variable speed drive connected to a pump tothereby control the second fluid flow through the pump based on thedetermined modified flow.

In some embodiments, one or more methods as described herein may includemaintaining the difference between the determined ratio and thepre-selected set point ratio within a pre-selected error range. Forexample, the pre-selected error range may be in the range of about 1.0%to −1.0%, about 0.5% to about −0.5%, about 0.25% to about −0.25%, about0.1% to about −0.1%, or about 0.05% to about −0.05%, based on thepre-selected set point.

In some embodiments, one or more methods as described herein may includedetermining a flow rate of the first fluid flow, which is gravity-fed,based on the signals received from the tank flow meter and the boosterflow meter. In some embodiments, the pressure of the first fluid flowmay be about equal to pressure of the second fluid flow at the junctionof the blended fluid pipe. In some embodiments, one or more methods asdescribed herein may include controlling a flow control valve in fluidcommunication with the second fluid flow to thereby control the secondfluid flow based on the determined modified flow. In some embodiments,one or more methods may include controlling a flow control valve influid communication with the second fluid flow to thereby maintainpressure at the tank flow meter between about 15 psi and about 25 psi.

In one or more embodiments, for example, methods for admixing threehydrocarbon liquids from a plurality of tanks into a single pipeline mayinclude determining percentages of flow rates of a first fluid flow, asecond fluid flow, and a third fluid flow in a blended fluid flow basedon signals received from a second tank flow meter in fluid communicationwith the second fluid flow, a third tank flow meter in fluidcommunication with the third fluid flow, and a booster flow meter influid communication with the blended fluid flow. In such embodiments,the blended fluid flow may include a blended flow of the first fluidflow, the second fluid flow, and the third fluid flow. In someembodiments, such methods may include comparing the determinedpercentages to pre-selected percentages to thereby determine modifiedflows of the second fluid and the third fluid in order to drive thedetermined percentages toward the pre-selected percentages. In someembodiments, such methods may include controlling at least one of asecond variable speed drive connected to a second pump and a thirdvariable speed drive connected to a third pump to thereby control atleast one of the second fluid flow and the third fluid flow based on thedetermined modified flows.

In some embodiments, one or more methods as described herein may includemaintaining the difference between the determined percentages and thepre-selected percentages within a pre-selected error range. For example,in some embodiments, the pre-selected error range may be in the range ofabout 1.0% to −1.0%, about 0.5% to about −0.5%, about 0.25% to about−0.25%, about 0.1% to about −0.1%, or about 0.05% to about −0.05%, basedon the pre-selected percentages.

In some embodiments, one or more methods as described herein may includedetermining a flow rate of the flow of the first fluid based on thesignals received from the second tank flow meter, the third tank flowmeter, and the booster flow meter. In some embodiments, pressures of thefirst fluid flow, second fluid flow, and third fluid flow may be aboutthe same at the junction of blended fluid pipe. In some embodiments, oneor more methods as described herein may include controlling at least oneof a second flow control valve in fluid communication with the secondfluid flow and a third flow control valve in fluid communication withthe third fluid flow to thereby control at least one of the second fluidflow and the third fluid flow based on the determined modified flows. Insome embodiments, one or more methods as described herein may includecontrolling a second flow control valve in fluid communication with thesecond fluid flow and a third flow control valve in fluid communicationwith the third fluid flow to thereby maintain pressure at each of thesecond tank flow meter and the third tank flow meter between about 15psi and about 25 psi.

FIGS. 6A through 6B are schematic diagrams of a two-component in-linemixing system positioned at a tank farm to admix two hydrocarbon liquidsfrom separate tanks into a single pipeline according to an embodiment ofthe disclosure. The in-line mixing system 600 may include two tanks(e.g., tank A 618 and tank B 620), three tanks, or more tanks, as notedabove. Tank A 618 may store a less dense or denser liquid than that ofthe liquid stored in tank B 620, depending on the final blend (in otherwords, Tank A 618 may store a liquid of a different density than that oftank B 620). Each tank (e.g., tank A 618 and tank B 620) may include orbe connected to and in fluid communication with output pipes (e.g., afirst output pipe 614 and a second output pipe 616, respectively).Output pipe 614 may attach directly to a blend pipe 612. The flow ofliquid stored in tank A 618 through the output pipe 614 may be gravitybased or gravity-fed, as described above. Such a flow may be affected bythe diameter of the output pipe 614 (e.g., smaller diameter pipes mayincrease pressure while decreasing flow and larger diameter pipes maydecrease pressure while increasing flow). In an embodiment, output pipe616 may be connected to and in fluid communication with a flow controldevice 608 (also referred to as a mechanical flow controller, a flowcontrol apparatus, and/or flow control subsystem). In an example, asensor 604 may be connected to and/or in fluid communication with eitherthe output pipe 616, the flow control device 608, or tank 620. Further,the flow control device 608 may include sensors (e.g., the sensorsincluding the functionality of sensor 604 and/or other functionality,such as the capability to provide a flow rate, pressure, and/or othervariables of the in-line mixing system 600). The flow control device 608may further be connected to and in fluid communication with a mixingpipe 613. The mixing pipe 613 and first output pipe 614 may be connectedto and in fluid communication with a blend pipe 612. The blend pipe 612may admix or mix the liquid flowing from tank A 618 and tank B 620(e.g., a first liquid and second liquid, respectively) during a blendingoperation. A sensor 602, as illustrated in FIG. 6B, may be connected toand/or in fluid communication with the output pipe 614. A sensor 610 maybe connected to and/or in fluid communication with the blend pipe 612.The sensor 602 and sensor 610 may be the same type of sensor as sensor604.

In an example, a blending or mixing process or operation may include twoor more liquids (e.g., the liquid stored in tank A 618 and tank B 620).The two or more liquids may be hydrocarbon liquids (e.g., petroleumliquids and/or renewable liquids). The density or gravity may or may notbe known based on various configurations of the tank farm. For example,upon delivery of a liquid, a user may receive the density or gravity oran estimate density or gravity, based on the type of liquid and/or on aform or ticket. In another example, the liquid delivered to a tank maybe of a certain type (i.e., heavy blend crude oil, light blend crudeoil, other types of hydrocarbon liquids, and/or renewable liquids) andmay be associated with an estimated density or gravity (e.g., for aheavy blend crude oil an API of about 30 degrees or less and for a lightblend crude oil an API of higher than 30 degrees). In another example,one density or gravity may be unknown (e.g., a particular tank or pipemay not include a sensor or meter, such as tank A 618 or output pipe 614in FIG. 6A), while all or some other densities or gravities may be knownor measured based on various sensors or meters disposed throughout thein-line mixing system 600 (e.g., sensor 604). In another example, when adensity or gravity is unknown, a sensor or meter (e.g., sensor 602and/or sensor 604 and sensor 610) may be utilized to determine anotherdensity or gravity and, based on the other density or gravity (forexample, the density or gravity of the second liquid and the blendliquid), the controller 606 may determine the unknown density orgravity. Such sensors or meters may be in signal communication with thecontroller 606. As noted, approximate, but inexact, densities orgravities may be known. In another example, the densities or gravitiesof all liquids to be blended may be measured via sensors or meters.

As used herein, “signal communication” refers to electric communicationsuch as hard wiring two components together or wireless communication,as understood by those skilled in the art. For example, wirelesscommunication may be Wi-Fi®, Bluetooth®, ZigBee, forms of near fieldcommunications, or other wireless communication methods as will beunderstood by those skilled in the art. In addition, signalcommunication may include one or more intermediate controllers, relays,or switches disposed between elements that are in signal communicationwith one another.

In an example, the sensors (e.g., sensor 602, sensor 604, and othersensors as will be described below) may be hydrometers, gravitometers,densitometers, density measuring sensors, gravity measuring sensors,pressure transducers, flow meters, mass flow meters, Coriolis meters,other measurement sensors to determine a density, gravity, or othervariable as will be understood by those skilled in the art, or somecombination thereof. In such examples, the sensors may measure thedensity and/or gravity of a liquid, the flow of the liquid, and/or thepressure of the liquid. As noted above, the controller 606 may be insignal communication with the sensors or meters. The controller 606 maypoll or request data from the sensors at various points in a blendingoperation. While a variety of sensors may be utilized, a hydrometer maybe preferred as, typically, hydrocarbon products are characterized byAPI gravity and a hydrometer may measure the specific gravity of aliquid. Thus, the controller 606 may convert an input API gravity onceto specific gravity for further determinations and/or calculations. Amass flow meter or Coriolis meter may also be preferred, as such metersmay measure flow and density. While such meters may potentially requireconversion of density to gravity, the use of such meters may reduce thetotal amount of equipment to use. Further, the sensor or meter may be influid communication with a liquid to measure the density or gravity ormay indirectly measure density or gravity (e.g., an ultrasonic sensor).In other words, the sensor or meter may be a clamp-on device to measureflow and/or density indirectly (such as via ultrasound passed throughthe pipe to the liquid).

As noted above, the sensors (sensor 602, sensor 604, and other) maymeasure the density or gravity of a liquid and/or a user may enter orthe controller 606 may store a density or gravity. The controller 606may be configured to perform the determination or calculations describedherein based on either density, gravity, specific gravity, or APIgravity. The controller 606 may be configured to convert any givenmeasurement based on the type of determinations or calculations (e.g.,determinations or calculations based on density, gravity, specificgravity, or API gravity). For example, a user may enter an API gravityfor a liquid at a user interface in signal communication with thecontroller. 606. The controller 606, may convert the entered API gravityto a specific gravity. In such examples, the sensors disposed throughoutthe system may measure the gravity of other liquids. In another example,the sensors may provide different measurements, e.g., density, and thecontroller 606 may further convert those measurements to gravity. Inanother example, the controller 606 may convert the entered API gravityto density. In such examples, the sensors disposed throughout the systemmay measure the density of other liquids. In another example, thesensors may provide different measurements, e.g., gravity, and thecontroller 606 may further convert those measurements to density.

As noted, the in-line mixing system 600 may perform various blending ormixing operations or processes. Rather than base control of the flowcontrol device 608 on just the flow and/or mix ratio of the liquids tobe blended, the in-line mixing system 600 may base control of the flowcontrol device 608 on the density or gravity of the liquids to beblended and a target blend density or gravity (in other words, thetarget density or gravity, being a density or gravity that may be soughtor desired for the final blend, may be utilized, rather than utilizationof just a mix ratio and/or flow of liquids to be blended). As noted,various liquids may be blended via the blend pipe 612. Further, one ormore densities or gravities of liquids to be blended (e.g., the densityor gravity of liquid stored in tank B 620) may be known or measured andanother unknown (e.g., the density or gravity of liquid stored in tank A618). As the blending or mixing operation or process starts, thecontroller 606 may determine or obtain a density or gravity from anyavailable sensors of the in-line mixing system 600 (e.g., from sensor604, sensor 610, and, if available, sensor 602) or from an input (e.g.,via a user interface). Based on the density or gravity obtained from thesensors (e.g., sensor 604 and sensor 610), the controller 606 maydetermine the density or gravity of the liquid of unknown density. Asnoted, sensors (e.g., sensor 604, sensor 610, and, if present, sensor602) may be disposed throughout the in-line mixing system 600 orincluded in flow control devices to measure all densities.

In the blending or mixing operation or process, a blend may be blendedto a target blend density or gravity. In other words, the blending ormixing operation or process may be based on a target blend density orgravity. A target blend density or gravity may be set or preset (inother words, loaded into or stored in) in the controller 606. The targetblend density or gravity may be set via a user interface in signalcommunication with the controller 606. For example, a user may set thetarget blend density or gravity at the user interface and the userinterface may send or transmit the target blend density or gravity tothe controller 606. In another example, the target blend density orgravity may be determined based on a particular or specified end productor blend. For example, a blending or mixing operation or process may beset to blend a high-volatile bituminous mixture or blend. In such ablend, an ideal or target blend density or gravity may be an API gravityof about 30 degrees. In such examples, the end product or blend (e.g.,the high-volatile bituminous mixture or blend) API gravity may beincluded in or preset in the controller 606. In another example, a userinterface may include a selectable list of various options for endproducts or blends. Based on the selected end product or blend, a targetblend density or gravity may be set for a blending or mixing operationor process.

As the blending or mixing operation or process is initiated, thecontroller 606 may obtain or determine the density or gravity from eachof the tanks (e.g., tank A 618 and tank B 620) at the tank farm. Thecontroller 606 may further include, determine, or obtain an initial mixratio and/or flow rate for any flow control devices in the in-linemixing system 600 (e.g., flow control device 608). In an example, thedensity or gravity of each liquid to be blended may be a known value.Further and as noted above, the density or gravity of each liquid to beblended may be entered into the user interface and sent or transmittedto the controller 606. In another example, each tank (e.g., tank A 618and tank B 620) may include sensors or meters (for example, sensor 602and sensor 604). In other examples, sensors or meters (e.g., sensor 602and sensor 604) may be disposed on or added onto the pipe (e.g., thefirst output pipe 614 and second output pipe 616). For example, thesensors or meters may be clamp-on sensors or may be integrated into oronto the pipe or components of the pipe (such as a pump or flow controlvalve, as described above). In such examples, prior to or just after theinitiation of the blending or mixing operation or process, thecontroller 606 may determine or obtain the density or gravitymeasurements of the liquids to be blended from the sensors or meters (orobtain the density or gravity measurements where such measurements maybe stored, such as from another controller, sub-controller, or memory).The controller 606 may also obtain other data from the sensor or meters,such as flow rate, pressure, and/or other variables.

In yet other examples, one tank and pipeline associated with orcorresponding to the tank may not include a sensor or meter (in otherwords, tank A 618 may or may not include a sensor 602). If a density orgravity of a liquid to be blended is unknown and no sensor is availableto measure or determine the density or gravity, the controller 606 maydetermine the density or gravity based on the other determined orobtained densities or gravities, as well as the blend density or gravityobtained from sensor 610. For example, in FIG. 6A, a second density orgravity may be known or determinable (e.g., measurable via the sensor604 or a meter). As such, the controller 606 may determine the seconddensity or gravity. Further, the blended density or gravity may bedeterminable (as in, measureable via the sensor 610 or a meter). Yetfurther still, a ratio of the two liquids to be blended may be known (asin, the initial ratio of the liquids to be combined, such as a 50:50,60:40, 30:70 mix ratio and so on or a mix ratio from 1:99 to 99:1).Based on the ratio and the determined densities or gravities, theunknown density of a first liquid (e.g., the liquid stored in tank A618) may be determined, using, for example, the blended gravity as equalto the first ratio multiplied by the first density or gravity plus thesecond ratio multiplied by the second density or gravity (rearranged tosolve for the first density or gravity or the unknown value), as shownby the following equations:

${{Blended}\mspace{14mu}{Gravity}} = \begin{matrix}{{{First}\mspace{14mu}{Gravity}*{First}\mspace{14mu}{Ratio}} +} \\{{Second}\mspace{14mu}{Gravity}*{Second}\mspace{14mu}{Ratio}}\end{matrix}$${{First}\mspace{14mu}{Gravity}} = \frac{{{Blended}\mspace{14mu}{Gravity}} - {{Second}\mspace{14mu}{Gravity}*{Second}\mspace{14mu}{Ratio}}}{{First}\mspace{14mu}{Ratio}}$If a first density or gravity is unknown, but the second density orgravity and blended density or gravity are known, the controller 606 maydetermine the first density or gravity. For example, if a synthetic fuelof a specific gravity of 0.857 is to be mixed with a heavier liquid atan initial mix ratio of 50:50, the controller 606 may determine theunknown specific gravity after measuring the blended gravity at thestart of the blending operation, which may be, for example, 0.886.Utilizing the equations above, the controller 606 may determine that thespecific gravity of the heavy liquid is 0.915 (e.g.,((0.886−50%)*0.857)/50%).

If all densities or gravities are known or once all densities orgravities have been determined, the flow of the liquids to be blendedmay be adjusted as needed or at specified time intervals, to produce anaccurate and precise blend. The specified time interval may be aninterval set by a user at the user interface. In another example, thespecified time interval may be an interval set in the controller 606. Insuch examples, the specified time interval may be a constant value or avariable value (variable, for example, depending on known or unknowndensities or gravities). A specified time interval may be an interval of10 to 20 minutes. In such examples, the amount of specified timeintervals may be based on the length of a specified time interval andthe total length of the blending or mixing operation or process (e.g., ablend operation of 4 hours may include 12 to 24 specified time intervalsof 10 to 20 minutes).

In another example, the specified time intervals may vary in length oftime as the blending or mixing operation or process proceeds. Forexample, neither density or gravity of any of the tanks (e.g., tank A618 and tank B 620) may be known, while in other examples, an estimatemay be known (e.g., based on which liquid is heavy and which is light).In such examples, none of the tanks (e.g., tank A 618 and tank B 620)may include sensors or meter to determine densities or gravities, exceptfor the sensor 610 to measure the blend density or gravity. Further, thecontroller 606 may check the blend density or gravity (via sensor 610),to allow for adjustment of the flow or mix ratio of liquids, morefrequently near the beginning of the blending or mixing operation orprocess (e.g., at the first 30 minutes of the blending operation) todetermine an accurate (e.g., if each density or gravity is unknown) ormore accurate (e.g., if an estimate of one or more of the densities orgravities is known) estimate of each liquids density or gravity. Theblend density or gravity may be checked or determined, for example,every 1 to 5 minutes or 1 to 10 minutes for the beginning (e.g., thefirst 30 minutes) of the blending or mixing operation or process and theflow rate or mix ratio adjusted. Such frequent measurements andadjustments may allow for the controller 606 to estimate the densitiesor gravities of each of the liquids to allow for further and lessfrequent adjustments during the blending or mixing operation or process,to ensure an accurate blend near (e.g., within about 1% of the targetblend density or gravity) or at the target blend density or gravity.After such estimates are determined, the controller 606 may check blenddensity or gravity and adjust the flow rate or mix ratios of liquidsless frequently (i.e., every 10 to 20 minutes), until the blendingoperation is finished.

At the end of each specified time interval, the controller 606 maydetermine the current density or gravity of the blend at the blend pipe612. The controller 606 may then compare the current density or gravityto the target blend density or gravity. If there is a difference betweenthe current density or gravity to the target blend density or gravity,the controller 606 may determine a corrected ratio of the first liquidand second liquid to reach the target blend density or gravity. Based onthe corrected ratio, the controller 606 may adjust the flow, via a flowcontrol device, of at least one of the liquids (e.g., the controller606, via the flow control device 608, may adjust the flow rate of thesecond liquid from tank B 620, while maintaining the proper pressure).

In an embodiment the flow control device 608 may include a pump, ameter, a pressure transducer, a flow control valve, and/or somecombination thereof. In another example, the sensor 604 may be a part ofthe flow control device 608. In another example, the sensor 604 may beincluded with or a part of the meter of the flow control device 608(e.g., a Coriolis meter, to measure flow and density). In such examples,each component of the flow control device 608 may be in signalcommunication with the controller 606. The flow control device 608 mayallow for mix ratio adjustments of the liquids being blended thereby toadjust the density or gravity. For example, the flow control device 608may, as noted, include a flow control valve. The flow control valve mayadjust the flow of the liquid based on opening or closing/pinching theflow control valve. In another example, the flow control device 608 mayinclude a pump and variable speed drive. The variable speed drive mayincrease/decrease the speed of the pump to increase/decrease the flowrate of a liquid to adjust the ratio of liquids to be blended.

FIGS. 7A through 7B are schematic diagrams of a three-component in-linemixing system 700 positioned at a tank farm to admix three hydrocarbonliquids from separate tanks into a single pipeline according to anembodiment of the disclosure. As described above, a tank farm mayinclude two or more tanks (e.g., tank A 718, tank B 720, and tank 724).In such examples, the tank farm may include extensive piping, as well asnumerous other components, such as flow control devices 708, 728,various sensors 702, 704, 710, 722, and a controller 706. In suchexamples, a blending or mixing operation or process may include at leasttwo of the tanks or all three tanks. In such operations or processes,various initial ratios may be utilized (e.g., 50:45:5, 60:30:10, and soon). Further, a blend may be based on target blend density or gravity(the ratio determined based on the desired blend density or gravity). Insuch examples, once all the densities or gravities are gathered, thecontroller 706 may determine the actual blend density or gravity, viathe sensor 710 at the blend pipe 712. Based on the target blend densityor gravity compared to the actual blend density or gravity, as well asthe current liquid ratio and/or a target ratio, the controller 706 mayadjust the flow of one or more of the liquids in the blend while theblending or mixing operation or process occurs.

FIGS. 8A through 8B are schematic diagrams of a multi-component in-linemixing system 800 positioned at a tank farm to admix two or morehydrocarbon liquids from separate tanks into a single pipeline accordingto an embodiment of the disclosure. In such examples, the tank farm mayinclude any number of tanks (e.g., tank A 802, tank B 810, and tank C818 to tank N 826) to store various liquids for various blendingoperations. In such examples, different tanks may be used for differentblending operations. In other words, two or more tanks may be active ata time, while other tanks may be de-active (as in, not utilized in ablending operation). Such tanks may store particular liquids notutilized for specific blends or may be empty at that particular point intime. Thus, various amounts of liquids may be blended in such a tankfarm (from 3 component blending to 5 component blending or more).

As noted, the tank farm may include various components and some tanksmay utilize the same components (as in, tank B 810 when active may use aset of components, while tank C 818 remains de-active and tank C 818 mayuse the same set of components, while tank B 810 remains de-active). Thecomponents utilized at the tank farm may include flow control devices816, 824, 832, various sensors 804, 812, 820, 828, 836, and a controller838.

FIG. 9 is a simplified diagram illustrating a control system formanaging a multi-component in-line mixing system according to anembodiment of the disclosure. The control system, as described herein,may be a controller 901, one or more controllers, a PLC, a SCADA system,a computing device, and/or other components to manage a blendingoperation. The controller 901 may include one or more processors (e.g.,processor 902) to execute instructions stored in memory 904. In anexample, the memory 904 may be a machine-readable storage medium. Asused herein, a “machine-readable storage medium” may be any electronic,magnetic, optical, or other physical storage apparatus to contain orstore information such as executable instructions, data, and the like.For example, any machine-readable storage medium described herein may beany of random access memory (RAM), volatile memory, non-volatile memory,flash memory, a storage drive (e.g., hard drive), a solid state drive,any type of storage disc, and the like, or a combination thereof. Asnoted, the memory 904 may store or include instructions executable bythe processor 902. As used herein, a “processor” may include, forexample one processor or multiple processors included in a single deviceor distributed across multiple computing devices. The processor 902 maybe at least one of a central processing unit (CPU), asemiconductor-based microprocessor, a graphics processing unit (GPU), afield-programmable gate array (FPGA) to retrieve and executeinstructions, a real time processor (RTP), other electronic circuitrysuitable for the retrieval and execution instructions stored on amachine-readable storage medium, or a combination thereof.

The instructions may include an instruction 906 to obtain or determine afirst density or gravity. In such examples, at the beginning of or priorto start of a blending operation, the controller 901 may obtain thefirst density or gravity from a user (e.g., the density or gravityentered via a user interface). In another example, the controller 901may obtain the first density or gravity from a sensor. The controller901 may obtain the first density or gravity from a ticket or order slip(or another form including such data). In another example, thecontroller 901 may determine the density or gravity based on other knowndensities or gravities. The controller 901 may include the first densityor gravity as a preset value. In such examples, a particular tank may bestore the same liquid for each blending operation. As such, the densityor gravity of the liquid may be the same or slightly different perbatch. The instructions may include an instruction 908 to obtain asecond density or gravity, similar to that of or the same asinstructions 906. In other words, the second density or gravity may beobtained via a user at a user interface, via measurement (as in,measurement from a sensor), via determination based on othermeasurements and/or data, or via a preset density or gravity.

The instructions may include an instruction 910 to obtain a target blenddensity or gravity. Such a target blend density or gravity may bedetermined based on the product to be blended or mixed. In anotherexample, the target blend density or gravity may be based on user inputvia a user interface. In yet another example, the target blend densityor gravity may be preset or stored in the memory 904 of the controller901. The instructions may include an instruction 910 to, after aspecified time interval, obtain or determine the actual blend density orgravity. Such instructions 910 may determine the actual blend density orgravity based on a measurement from a blend sensor 920.

After reception of the actual blend density or gravity, the controller901 may compare the actual blend density or gravity to the target blenddensity or gravity. The instructions may include an instruction 914 to,based on a difference between the actual blend density or gravity andthe target blend density or gravity, determine a corrected ratio. Inother words, the corrected ratio may be the mix ratio of the first andsecond liquid (or any other liquids to be blended) transported to ablend pipe for mixing.

The instructions may include instructions 916 to, in response to adetermination of a corrected ratio, adjust the flow of one or more ofthe liquids, based on the corrected ratio. Such adjustments may occurduring operation or execution of the blending or mixing operation orprocess. For example and as noted, the target blend may be a 30 APIbend. If at a current ratio of 60:40, the blend is currently at 25 API,the lighter of the two fluids flow rate may be increased to increase theAPI gravity of the overall blend (e.g., an increase from 60:40 to 50:50,40:60, etc. to increase the API gravity).

For example, a blend may be a 60:40 (first liquid:second liquid) blendwith a target of an API of 30 degrees. In such examples, the firstliquid, which may be a heavier liquid, may be fed via gravity to theblending pipe at a constant flow and pressure and the second liquid,which may be a lighter liquid, may be fed to the blend pipe, via a flowcontrol device 922, at a set flow and/or pressure. At the beginning ofsuch a blending operation, the current or actual blend API may be 28degrees. Based on the difference between the target blend gravity andthe actual blend gravity and the new determined ratio, the flow controldevice 922 may increase the flow of the second liquid during theblending operation, thus adjusting the mix ratio or increasing the ratioof the second liquid in the blend to ensure that the API is increased,so as to reach the target API. Such operations may ensure an accurateblend that meets the target blend density or gravity.

Other instructions may include instructions to obtain a current flowrate and/or mix ratio based on data obtained from the flow controldevice 922 and/or the blend sensor 920. Further, at the initiation of ablending operation the controller 901 may set the initial flow rate ofliquids from each tank. The initial flow rate may be based on a knownfirst density and second density, on an estimate of the first densityand second density, or on an arbitrary mix ratio (e.g., an initial mixratio may be 50:50 and, as such, the flow rate, via the flow controldevice 922, may be set to an appropriate setting to allow for the firstliquid and second liquid to mix at the 50:50 ratio). In other examples,the flow rate of one liquid, e.g., the first liquid, may be a constantvalue, as the liquid may be gravity fed to the blend pipe. In suchexamples, the flow rate or mix ratio may be utilized to determineunknown densities or gravities.

FIG. 10 is another simplified diagram illustrating a control system formanaging a multi-component in-line mixing system according to anembodiment of the disclosure. In such examples, the controller 1001 mayinclude instructions to measure or obtain a density or gravity fromvarious sensors (e.g., blend sensor 1020, sensor 1012, sensor 1014,sensor 1016, sensor N 1018, etc.) or from a user interface 1030.Further, the controller 1001 may include instructions to determine acorrected ratio based on the determined or obtained densities orgravities. Further still, the controller 1001 may include instructionsto adjust the flow and/or pressure of one or more of the various liquidsbeing blended, via one or more flow control devices (e.g., flow controldevice 1022, flow control device 1024, flow control device 1026, flowcontrol device N 1028, etc.), based on the determined or obtaineddensities or gravities. Such adjustments may occur during continuousoperation of the blending or mixing operations or processes.

In an example, the sensors (e.g., blend sensor 1020, sensor 1012, sensor1014, sensor 1016, sensor N 1018, etc.) may provide measurements as adensity or as a gravity (e.g., a specific gravity). However, some valuesmay be entered via the user interface as an API gravity. For example, ifthere are no sensors associated with a first tank or first output pipe,a user may enter the density or gravity of the first liquid at the userinterface 1030. The user may enter such a value as an API gravity, whichmay typically be utilized to describe characteristics of hydrocarbonliquids. As such, the controller 1001 may include instructions toconvert measurements, whether from density or specific gravity, to anAPI gravity or to convert an API gravity to a density or specificgravity. In another example, the user interface 1030 may include anoption to select the type of measurement to enter when entering in adensity or gravity (e.g., a list or drop-down list includingmeasurements as density, specific gravity, or API gravity).

FIG. 11 is another simplified diagram illustrating a control system formanaging a multi-component in-line mixing system according to anembodiment of the disclosure. As noted above, the controller 1001 mayinclude instructions 1006 to measure or obtain the density or gravity ofliquid associated with a corresponding sensor or meter (e.g., blendsensor 1020). In some cases, a tank farm may include a sensor (e.g.,blend sensor 1020) corresponding to the blend pipe, rather than a sensorfor the blend pipe and for each tank or pipe corresponding to each tank.In such cases, the density or gravity from each tank may be known, inputat a user interface 1030, or be estimated as described above.

FIGS. 12 through 13 are flow diagrams, implemented in a controller, formanaging a multi-component in-line mixing system according to anembodiment of the disclosure. The method is detailed with reference tothe controller 1001 and system 1000 of FIG. 10. Unless otherwisespecified, the actions of methods 1200 and 1300 may be completed withinthe controller 1001. Specifically, methods 1200 and 1300 may be includedin one or more programs, protocols, or instructions loaded into thememory of the controller 1001 and executed on the processor or one ormore processors of the controller 1001. The order in which theoperations are described is not intended to be construed as alimitation, and any number of the described blocks may be combined inany order and/or in parallel to implement the methods.

At block 1202, the controller 1001 may obtain or determine a firstdensity or gravity from a first sensor 1012. In another example, thecontroller 1001 may obtain the first density or gravity from the userinterface 1030 (e.g., based on an input from a user). In anotherexample, the first density or gravity may be determined based on otherknown or determined densities or gravities. At block 1204, thecontroller 1001 may obtain or determine a second density or gravity froma second sensor 1014 (similar to that of obtaining or determining thefirst density or gravity from the first sensor 1012). In other examples,more densities or gravities, based on other liquids to be blended in ablending or mixing operation or process, may be obtained from othersensors located or disposed at the tank farm (e.g., a third sensor 1016,sensor N 1018, etc.).

At block 1206, a target blend density or gravity may be obtained. Insuch examples, the target blend density or gravity may be input at theuser interface 1030. The target blend density or gravity may be presetand stored in memory 1004. At block 1208, the controller 1001 maydetermine whether a specified time interval has passed. If the specifiedtime interval has not passed, the controller 1001 may continue to checkwhether the specified time interval has passed after a certain period oftime. If the specified time interval has passed, the controller 1001 mayobtain an actual blend density or gravity from a third sensor (e.g.,blend sensor 1020) located at the blend pipe. The actual blend densityor gravity may be the density or gravity of a blended liquid comprisedof a ratio of the first liquid, the second liquid, and/or other liquidsincluded in the blend operation.

At block 1212 the controller 1001 may compare the target density orgravity to the actual blend density or gravity. If the target blenddensity or gravity is equal to the actual blend density or gravity, thecontroller 1001 may wait for the next specified time interval to pass.If the values are not equal, at block 1214, the controller 1001 maydetermine a corrected ratio, based on the densities or gravities of eachliquid being blended, the target blend density or gravity, and theactual blend density or gravity. In another example, prior todetermination of a corrected ratio the controller 1001 may convert anynumber of measurements to different types of measurements, depending oncontroller 1001 configuration and/or measurements obtained from sensorsdisposed throughout the system. For example, the controller 1001 may beconfigured to determine a corrected ratio based on gravity, while thesensors may measure density. In such examples, the controller 1001 maybe configured to convert the densities measured to gravities, prior toeither comparison or determination of the corrected ratio. In anotherexample, the controller 1001 may be configured to determine a correctedratio based on density, while the sensors may measure gravity. In suchexamples, the controller 1001 may be configured to convert the gravitiesmeasured to densities, prior to either comparison or determination ofthe corrected ratio. In another example, the controller 1001 may bereconfigured to perform determinations or calculations based on themeasurements performed by the sensors. In other words, a controller 1001may be reconfigured to perform determinations based on density orgravity if the sensors measure density or gravity, respectively.

At block 1216, the controller 1001 may adjust the flow, via the flowcontrol device of either the first liquid and second liquid (e.g., viaflow control device 1022 and flow control device 1024, respectively),the second liquid (e.g., via the flow control device 1024), otherliquids being blended (e.g., flow control device 1026, flow controldevice 1028, etc.), or a combination thereof.

For example, a first liquid from a first tank may be gravity-fed to theblend pipe. In such examples, the flow control device for the secondliquid of the second tank may adjust the flow of the second liquid, thuscontrolling or adjusting the mix ratio of the first liquid and secondliquid. Similar to the equations noted above, the new ratio may becalculated based on the first liquid's density or gravity, the secondliquid's density or gravity, the actual blend density or gravity, andthe target blend density or gravity. The following equation may beutilized to determine the corrected ratio (while the equation is shownutilizing gravity, density or API gravity may be utilized):

${Second}\mspace{14mu}{Ratio}{= \frac{{{Target}\mspace{14mu}{Blend}\mspace{14mu}{Gravity}} - {{First}\mspace{14mu}{Gravity}}}{{{First}\mspace{14mu}{Gravity}} - {{Second}\mspace{14mu}{Gravity}}}}$Based on the new second ratio, the flow control device may adjust theflow of the second liquid. In other examples, both the first liquid andsecond liquid may pass through a flow control device. In such examples,the first liquid flow and the second liquid flow may both be adjusted.While the equation described above is based on a two component blend,the equation may be utilized for a three or more component blend.

For FIG. 13, at block 1301, the controller 1001 may initiate a blendingprocess or receive a signal to initiate a blending process. In suchexamples, the controller 1001 may not begin the actual blending processuntil a first density or gravity and a second density or gravity aredetermined. In another example, the controller 1001 may start theblending process upon reception of the initiation signal or indicatorand determine the first and second densities or gravities as theblending process occurs.

At block 1302, the controller 1001 may determine whether a first densityor gravity of a first liquid from a first tank is known. If the firstdensity or gravity is unknown, at block 1304, the controller 1001 maydetermine the first density or gravity (e.g., via sensor, via theequations referenced above, or via a user interface 1030). At block1306, the controller 1001 may determine if a second density or gravityof a second liquid from a second tank is known. If the second density orgravity is unknown, at block 1308, the controller 1001 may determine thesecond density or gravity (e.g., via sensor, via the equationsreferenced above, or via a user interface 1030).

At block 1310, the controller 1001 may determine whether the targetblend density or gravity is known. If the target blend density orgravity is unknown, the controller 1001, at block 1312, may request thetarget blend density or gravity from a user (e.g., sending a prompt to auser interface indicating a target blend density or gravity may beentered to proceed). At 1314, if the target blend density or gravity hasnot been received the controller 1001 may wait for the target blenddensity or gravity. If the target blend density or gravity is received,the controller 1001, at block 1316, may determine the actual blenddensity or gravity, the blend density or gravity based on the density orgravity of the first and second liquid and the ratio the first andsecond liquid are blended or mixed at.

At block 1318, the controller 1001 may compare the blend density orgravity with the target blend density or gravity. If the blend densityor gravity and the target blend density or gravity do not match, atblock 1320 the controller 1001 may determine the corrected ratio, basedon the density or gravity of the first liquid, the second liquid, theblended liquid, and the ratio of the first liquid and second liquid. Atblock 1322, the controller 1001 may adjust any flow control devicespresent to adjust the flow of one or more of the liquids to be blendedor mixed.

At block 1324, the controller 1001 may determine whether the blendingprocess is finished. If the blending process is finished, the controller1001, at block 1326 may wait a specified time period and then determinethe blend density again. Once the blending process is finished, thecontroller 1001 may initiate another blending process.

EXPERIMENTAL

Experiments were conducted to test two-component and three-componentin-line mixing systems as described herein. Testing was conducted at apipeline origination station having a tank farm housing variousdifferent types of crude oil and other hydrocarbon liquids. In a firstblending operation run, two different types of crude were blended usinga two-component in-line mixing system (e.g., having a gravity-fed streamcontaining a first fluid and a controlled feed stream containing asecond fluid) with a target mix ratio of 50:50 (second fluid:firstfluid). The two-component blending operation run was conducted for threehours with constant measurement of the actual percentage of thecontrolled feed stream being delivered in the total blended fluid flow(e.g., based on the measured flow rate of the crude oil in thecontrolled feed stream).

Table 1 includes data from the two-component blending operation runperformed at the pipeline origination station. As shown in Table 1, theaverage actual percentage of the controlled feed stream was 49.87% overthe duration of the three-hour two-component blending operation runbased on a target set point ratio of 50:50 in the blended fluid flow. Asindicated in Table 1, this represents a 0.13% linear difference and a0.26% percent difference between the actual mix ratio and the target setpoint mix ratio. It should be noted that the percentage differencebetween the actual mix ratio and the target mix ratio would be expectedto be even lower if the blending operation testing run were to beconducted for a longer duration (e.g., for 6 hours, or 9 hours, or 12hours, or more).

TABLE 1 Average Actual Target Linear Percent Percentage (%) Percentage(%) Difference (%) Difference (%) 49.8684% 50% 0.132% −0.2632%

In a separate blending operation run, three different types of crude oilwere blended using a three-component in-line mixing system (e.g., havinga gravity-fed stream containing a first fluid and two controlled feedstreams containing a second fluid and a third fluid, respectively) witha target mix ratio of 50:46:4 (third fluid:second fluid:first fluid).The three-component blending operation run was conducted for six hourswith constant measurement of the actual percentage of both controlledfeed streams being delivered in the total blended fluid flow (e.g.,based on the measured flow rate of the crude oil in each of thecontrolled feed streams).

Table 2 includes data from a blending operation run performed at apipeline origination station using a three-component in-line mixingsystem according to the disclosure. As shown in Table 2, the averageactual percentage of the third fluid was 49.95% over the duration of thesix-hour three-component blending operation run based on a target setpoint ratio of 50:46:4 (third fluid:second fluid:first fluid) in theblended fluid flow. As indicated in Table 2, this represents a 0.05%linear difference and a 0.09% percent difference between the actualpercentage of the third fluid and the target set point percentage of thethird fluid. As also shown in Table 2, the average actual percentage ofthe second fluid was 49.89% over the duration of the six-hourthree-component blending operation run based on a target set point ratioof 50:46:4 (third fluid:second fluid:first fluid) in the blended fluidflow. As indicated in Table 2, this represents a 0.11% linear differenceand a 0.25% percent difference between the actual percentage of thesecond fluid and the target set point percentage of the second fluid. Itshould be noted that the percentage difference between the actual mixpercentages and the target mix percentages would be expected to be evenlower if the blending operation testing run were to be conducted for alonger duration (e.g., for 9 hours, 12 hours, 15 hours, or more).

TABLE 2 Average Actual Target Linear Percent Percentage - Percentage -Difference Difference Third Fluid (%) Third Fluid (%) (%) (%) 49.9547%50% 0.045% −0.0906% Average Actual Target Linear Percent Percentage -Percentage - Difference Difference Second Fluid (%) Second Fluid (%) (%)(%) 45.8859% 46% 0.114% −0.2481%

This application is a continuation of U.S. Non-Provisional applicationSer. No. 17/247,704, filed Dec. 21, 2020, titled “METHODS AND SYSTEMSFOR INLINE MIXING OF HYDROCARBON LIQUIDS,” now U.S. patent Ser. No.10,990,114, issued Apr. 27, 2021, which claims priority to, and thebenefit of U.S. Provisional Application No. 62/954,960 filed Dec. 30,2019, titled “METHOD AND APPARATUS FOR INLINE MIXING OF HEAVY CRUDE,”U.S. Provisional 62/705,538 filed Jul. 2, 2020, titled “METHODS ANDSYSTEMS FOR INLINE MIXING OF PETROLEUM LIQUIDS,” and U.S. Provisional63/198,356 filed Oct. 13, 2020, titled “METHODS AND SYSTEMS FOR INLINEMIXING OF PETROLEUM LIQUIDS,” the disclosures of which are incorporatedherein by reference in their entirety.

In the drawings and specification, several embodiments of systems andmethods to provide in-line mixing of hydrocarbon liquids have beendisclosed, and although specific terms are employed, the terms are usedin a descriptive sense only and not for purposes of limitation.Embodiments of systems and methods have been described in considerabledetail with specific reference to the illustrated embodiments. However,it will be apparent that various modifications and changes may be madewithin the spirit and scope of the embodiments of systems and methods asdescribed in the foregoing specification, and such modifications andchanges are to be considered equivalents and part of this disclosure.

The invention claimed is:
 1. A method of admixing hydrocarbon liquidsfrom a plurality of tanks into a single pipeline to provide in-linemixing thereof, the method comprising: permitting a first hydrocarbonfluid to flow from a first tank to a first output pipe; pumping, at apressure, a second hydrocarbon fluid from a second tank to a mixingpipe; admixing the first hydrocarbon fluid from the first output pipeand the second hydrocarbon fluid from the mixing pipe in a blended fluidpipe to create a blended fluid; determining, via one or morecontrollers, a first hydrocarbon flow rate of the first hydrocarbonfluid in the first output pipe based on a blended fluid flow rate of theblended fluid through a blended fluid pipe flow meter and a secondhydrocarbon flow rate of the second hydrocarbon fluid through a tankflow meter; comparing, via the one or more controllers, a ratio of thesecond hydrocarbon flow rate and the first hydrocarbon flow rate to apre-selected set point ratio; and controlling, via the one or morecontrollers, the pressure of the second hydrocarbon fluid to modify thesecond hydrocarbon flow rate and drive the ratio toward the pre-selectedset point ratio.
 2. The method of claim 1, further comprisingmaintaining, via the one or more controllers, any difference between theratio and the pre-selected set point ratio within a pre-selected errorrange.
 3. The method of claim 1, wherein the first pressure results fromforce of gravity on the first hydrocarbon fluid contained in the firsttank.
 4. The method of claim 1, wherein controlling the second pressureof the second hydrocarbon fluid occurs by adjusting speed of a variablespeed pump, via the one or more controllers, that pumps the secondhydrocarbon fluid or adjusting, via the one or more controllers, a flowcontrol valve disposed in the mixing pipe.
 5. The method of claim 4,wherein adjusting the flow control valve maintains pressure upstreamthereof between about 15 psi and about 25 psi.
 6. A controller for anin-line mixing system for admixing hydrocarbon liquids from one or moretanks into a single pipeline, the controller comprising: a firstinput/output in signal communication with a flow control device, theflow control device to adjust a pressure of a second liquid from asecond pipe to a mixing pipe, the second pipe connected to a second tankof a tank farm, the controller configured to control the pressure of thesecond liquid via the flow control device; a first input in signalcommunication with a first sensor connected to the second pipe, thefirst sensor to measure the flow rate of the second liquid; and a secondinput in signal communication with a second sensor, the second sensorconnected to a blend pipe, the blend pipe connected to the mixing pipeand a first pipe of a first tank of a tank farm to store a first liquid,the blend pipe to mix the first liquid and second liquid to create ablend liquid, the second sensor to measure the flow rate of the blendliquid, such that the controller is configured to: after initiation of ablending operation: (1) obtain the flow rate from the first sensor andthe flow rate of the blend liquid from the second sensor via the firstinput and second input, respectively, (2) determine, based on the flowrate from the first sensor and the flow rate from the second sensor, theflow rate of the first liquid, and (3) in response to a differencebetween a ratio of the flow rate of the first liquid and the flow rateof the second liquid a target flow ratio: I. determine a corrected ratioof the of the flow rate of the first liquid and the flow rate of thesecond liquid, and II. adjust, via the flow control device and based onthe corrected ratio, the pressure of the second liquid during theblending operation.
 7. The controller of claim 6, wherein the flowcontrol device is one or more of a pump and flow control valve.
 8. Thecontroller of claim 7, wherein the flow control device further includesa spillback loop.
 9. The controller of claim 6, wherein the flow of thefirst fluid results from force of gravity on the first fluid containedin the first tank.
 10. The controller of claim 6, wherein the controlleris further configured to maintain any difference between the ratio andthe target flow ratio within a pre-selected error range.
 11. Thecontroller of claim 6, wherein adjustment of the flow control devicemaintains pressure upstream thereof between about 15 psi and about 25psi.